sect-2

Section 2: Installation & Commissioning

Chapter 1 - Installation

1.1 Introduction .............................................................................................. 2-11.1.1 Equipment positioning and environmental considerations .......... 2-21.1.2 Raised Floor Installation .............................................................. 2-21.1.3 Battery Location ........................................................................... 2-2

1.2 Preliminary Checks .................................................................................. 2-4

1.3 Connecting the UPS power cables ........................................................... 2-51.3.1 Cable entry ................................................................................... 2-51.3.2 Cable rating .................................................................................. 2-51.3.3 Cable connections ........................................................................ 2-61.3.4 Safety earth .................................................................................. 2-61.3.5 Cabling procedure ........................................................................ 2-6

1.4 Battery Installation ................................................................................. 2-101.4.1 Battery circuit breaker boxes ..................................................... 2-11

Chapter 2 - Commissioning Procedure

2.1 Introduction ............................................................................................ 2-13

2.2 Procedure overview ................................................................................ 2-14

2.3 Pre-commissioning Checks .................................................................... 2-162.3.1 Power cable installation ............................................................. 2-162.3.2 Control cable installation ........................................................... 2-172.3.3 Battery Power Cable Installation ............................................... 2-192.3.4 Printed circuit board configuration jumper selection ................. 2-202.3.5 Pre-power checks ....................................................................... 2-262.3.6 Initial utility power connection .................................................. 2-28

2.4 Start-Up and software commissioning ................................................... 2-292.4.1 Operator Control Panel display screen ...................................... 2-292.4.2 Applying power to the UPS ....................................................... 2-302.4.3 Password protection and operation ............................................ 2-302.4.4 Language Selection .................................................................... 2-312.4.5 Selecting the UPS SETUP parameters ....................................... 2-33

Setting the basic UPS configuration ................................ 2-34Setting the UPS working voltage parameters .................. 2-34Setting the UPS frequency parameters ............................ 2-35Setting the Battery parameters ......................................... 2-36

2.4.6 Selecting the UPS MAINTENANCE parameters ...................... 2-39Accessing the maintenance menu .................................... 2-39Entering the Serial Number ............................................. 2-39Entering the current Date and Time ................................. 2-40Entering the Service details ............................................. 2-40

S-2.FM5 - Issue 2 Dated 21/08/97 i

SECTION 2 - Installation & Commissioning 7200 Series UPS Service Manual

2.4.7 Selecting the UPS FUNCTION parameters ............................... 2-40Accessing the function menu ........................................... 2-40Setting the Battery Test parameters ................................. 2-42Setting the Generator parameters ..................................... 2-43Setting the Panel Setup selections .................................... 2-44Setting the NEXT PAGE selections ................................ 2-46

2.5 Power checks .......................................................................................... 2-472.5.1 Applying power to the UPS ....................................................... 2-472.5.2 Monitoring & recording the UPS operating parameters ............ 2-472.5.3 Power module ON/OFF functional checks ................................ 2-49

Accessing the ON/OFF menu screen ............................... 2-49Inverter test ...................................................................... 2-50Bypass test ....................................................................... 2-50Rectifier and battery autonomy test ................................. 2-50

2.5.4 Battery test ................................................................................. 2-512.5.5 Emergency remote power off check .......................................... 2-532.5.6 Battery boost test (if applicable) ................................................ 2-532.5.7 On-Generator test (if applicable) ............................................... 2-54

2.6 Commissioning conclusion (‘single module’) ....................................... 2-55

2.7 Parallel System Start Up (‘1+1’ System) ............................................... 2-552.7.1 Initialisation ............................................................................... 2-552.7.2 Parallel logic PCB calibration .................................................... 2-56

2.8 Testing the Complete Parallel System .................................................... 2-572.8.1 Module starting .......................................................................... 2-572.8.2 Inverter bypass re-transfer checks ............................................. 2-57

Redundant configuration system power checks ............... 2-58Non-redundant configuration system power checks ........ 2-59

2.9 Commissioning conclusion (‘1+1’ system) ............................................ 2-60

2.10 Voltage and Frequency Conversion ..................................................... 2-612.10.1 Rating considerations and battery sizing ................................. 2-612.10.2 Hardware conversion ............................................................... 2-612.10.3 Software conversion ................................................................. 2-62

Setting the UPS working voltage parameters .................. 2-63Setting the UPS frequency parameters ............................ 2-63Setting the Battery parameters ......................................... 2-64

2.10.4 Calibration conversions ........................................................... 2-67Recalibrating the battery charging voltages ..................... 2-67Completion of UPS SETUP configuration ...................... 2-68

Chapter 3 - Converting single (pre Jan 1997) units to 1+1 capability

3.1 Introduction ............................................................................................ 2-69

3.2 Conversion Procedure ............................................................................ 2-69

ii S-2.FM5 - Issue 2 Dated 21/08/97

Section 2:

Chapter 1 - Installation

1.1 Introduction

WARNING Do not apply electrical power to the UPS equipment before the arrival of the com-missioning engineer.

WARNING The UPS equipment should be installed by a qualified engineer in accordancewith the information contained in this chapter and the drawing package shippedinside the UPS cabinet.

WARNING Battery hazards:

Special care should be taken when working with the batteries associated with thisequipment. When connected together, the battery terminal voltage will exceed400 Vdc and is potentially lethal.Eye protection should be worn to prevent injury from accidental electrical arcs.Remove rings, watches and all metal objects.Only use tools with insulated handles.Wear rubber gloves.If a battery leaks electrolyte, or is otherwise physically damaged, it should beplaced in a container resistant to sulphuric acid and disposed of in accordancewith local regulations.If electrolyte comes into contact with the skin the affected area should be washedimmediately.

This chapter contains information regarding the positioning and cabling of theUPS equipment and batteries.

Because every site has its peculiarities, it is not the aim of this chapter to providestep-by-step installation instructions, but to act as a guide as to the general proce-dures and practices that should be observed by the installing engineer.

1+11+1

Important Note: These instructions are written specifically for a ‘single-module’ installation. Ifyou are installing a two-module ‘1+1’ system you should follow the instructionsprovided for the ‘single-module’ installation and then complete the inter-modulecontrol cabling to complete the installation. If you are converting an early (preJanuary 1997) module for ‘1+1’ operation then refer to Chapter 3 and carry outthe necessary modifications prior to installing the module.

1+11+1

Options: There are several options available in conjunction with a ‘1+1’ configured sys-tem, such as common battery operation. Read the instructions that accompany anysuch option prior to commencing installation to understand their impact (if any)on the following procedure.

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SECTION 2 - Installation & Commissioning 7200 Series UPS Service ManualCHAPTER 1 - Installation Procedure

1.1.1 Equipment positioning and environmental considerations

The UPS cabinets are fitted with castors to facilitate ease of movement and posi-tioning. When the equipment has been finally positioned ensure the adjustablejacking feet are set so that the UPS will remain stationary and stable.

The UPS can be lifted using either a fork lift or a cradle. When lifting, take carenot to damage the castors or jacking feet located on the bottom of the unit.

WARNING Ensure the UPS weight is within the designated S.W.L. of any handling equip-ment. See the UPS specification for weight details.Do not move battery cabinets with the batteries fitted.

The UPS module should be located in a cool, dry, clean-air environment with ad-equate ventilation to keep the ambient temperature within the specified operatingrange. Where ventilation is poor and the ambient temperature high, a system ofextractor fans should be installed to aid cooling-air flow; and a suitable air filtra-tion system used where the UPS is to operate in a dirty environment.

Cables: All control cables should be screened and run in metal conduits (orducts) separate from the power cables; all conduits and ducts should be electrical-ly bonded to the metalwork of the cabinets to which they are connected.

Cooling air flow: All the models in the 7200 range are force-cooled by internalfans. Cooling air enters the cabinet through ventilation grills located at the bottomof the front doors and is exhausted through the fan grills located on the rear panel;you must therefore allow for a minimum gap of 250mm behind the unit to allowadequate air flow (See Figure 2-1).

Clearances: Clearance around the front of the equipment should be sufficient toenable free passage of personnel with the doors fully opened.

1.1.2 Raised Floor Installation

If the equipment is to be located on a raised floor it should be mounted on a ped-estal suitably designed to accept the equipment point loading. The installation di-agrams accompanying the system identify the location through which the cabinetcan be secured to the floor.

1.1.3 Battery Location

Temperature is a major factor in determining the battery life and capacity. Batterymanufacturers quote figures for an operating temperature of 20ºC. Operatingabove this temperature will reduce the battery life, yet operating below willreduce the battery capacity. In a normal installation the battery temperatureshould be maintained between 15ºC and 25ºC.

Batteries should be mounted in an environment where the temperature is consist-ent and even over the whole battery. Keep batteries away from main heat sourcesor draughty air flows etc.

Pedestals are required for the battery cabinets if they are to be installed on raisedfloors, in the same way as for the UPS cabinets.

2-2 s2-c1.fm5 - Issue 2 Dated 21/08/97

7200 Series UPS Service Manual SECTION 2 - Installation & CommissioningCHAPTER 1 - Installation Procedure

Figure 2-1: Installation Diagram

FRONT VIEW SIDE VIEW140

0

710

55

250 800

FRONT3

4

Adjustable fixing feet

Castors forease of movement

80

0605

40

710

125

200 85 10 200 125

92.5

BASE

REAR VIEW

5

3

REAR VIEW1 Entry panel for all power cables

2 Entry panel for all control cables

3 Air inlet ventilation grills

4 Minimum clearance from wall 250mm

5 Cabinet extractor fans - additional fans are fitted when the input harmonic filter is included

Weights

30kVA = 480kg. 40kVA = 540kg. 60kVA = 620kg.

s2-c1.fm5 - Issue 2 Dated 21/08/97 2-3


1.2 Preliminary Checks

Before you install the UPS hardware you should carry out the following prelimi-nary checks:

1. Verify that the UPS room satisfies the environmental conditions stipulated inthe equipment specification, paying particular attention to the ambient tem-perature and air exchange system.

2. After removing any packaging debris, visually examine the UPS and batteryequipment for transit damage, both internally and externally. Report any suchdamage to the shipper immediately.

3. Verify that the shipment is complete - e.g. that the battery contains the correctnumber of cells etc. Report any discrepancy immediately.

4. When you are satisfied that the equipment is complete and in good conditionmove it to its proposed final position.

Figure 2-2: Cable Entry Locations

Auxiliary terminal block (X3)

Castors

Control cables entry position

Adjustable fixing feet

Power cable entry panel

Main chassis earth busbar

2-4 s2-c1.fm5 - Issue 2 Dated 21/08/97


1.3 Connecting the UPS power cables

WARNING Before cabling-up the UPS, ensure that you are aware of the location and opera-tion of the external isolators that connect the UPS input/bypass supply at themains distribution panel.Check that these supplies are electrically isolated, and post any necessary warn-ing signs to prevent their inadvertent operation.

1.3.1 Cable entry

Cables enter the UPS modules via entry panels in the base of the cabinet. Asshown in Figure 2-2, separate entry points are provided for the power cables(which include the input, output and battery cables) and control cables (which in-cludes battery control, remote stop and remote communication wiring).

1.3.2 Cable rating

The input/output cables can be sized to suit the modules' rating according to Table2-1 below.

Table 2-1:

(nn) mm2 is the recommended minimum size according to BS7671 Table 4D1A(IEE regs. 16th Edition).

The following recommendations are guidelines only and superseded by localregulations and codes of practice where applicable:

1. The neutral conductor should be sized for 1.5 times the output/bypass phasecurrent.

2. The earth conductor should be sized at 2 times the output/bypass conductor(this is dependent on the fault rating, cable lengths, type of protection etc.).

3. BS7671 Table 4D1A applies to single core PVC-insulated, non armouredcable in an ambient temperature of 30ºC, according to fixing method 1 – sam-ples shown in Figure 2-3.

UPS RATING

(kVA)

NOMINAL CURRENT: AmpsRecommended Cable Size (mm2)

BUSBAR CONNECTION

STUD SIZE

Input Mainswith full battery

recharge

Bypass/Outputat full load

Battery at min.

battery voltage

Input/Output Cable

Terminations

U-V-W-N

Battery Terminat

ions+ve &

-ve380V 400V 415V 380V 400V 415V

30 64(16)

59(16)

56(16)

46(10)

44(10)

42(10)

82(25)

M6 Bolt M8 Bolt

40 85(25)

78(25)

73(25)

61(16)

58(16)

56(16)

110(35)

M6 Bolt M8 Bolt

60 128(35)

117(35)

109(35)

91(25)

87(25)

84(25)

163(50)

M6 Bolt M8 Bolt

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Figure 2-3: Cable fixing samples from method 1

1.3.3 Cable connections

The input (bypass) mains cables, UPS output cables and main battery cables areconnected to busbars fitted to the power isolator switches (lug terminations re-quired). The battery circuit breaker control cables and the external emergencystop cables (optional) are connected using female spade connectors to an auxiliaryterminal block identified as “X3” - (See Figure 2-5).

1.3.4 Safety earth

The safety earth busbar is located near the input and output power supply connec-tions as shown in Figure 2-5. The site safety earth cable must be connected to theearth busbar and bonded to each cabinet in the system and all cabinets and cabletrunking should be earthed in accordance with local regulations.

WARNING Failure to follow adequate earthing procedures can result in electric shock hazardto personnel, or the risk of fire, should an earth fault occur.

1.3.5 Cabling procedure

Once the equipment has been finally positioned and secured, connect the powercables as described in the following procedure.Study the connection diagram in Figure 2-5.

Input mains supply cables

1. Verify that the UPS equipment is totally isolated from its external powersource and all the UPS power isolators are open.

2. Connect the a.c. input supply cables between the mains distribution panel andthe UPS rectifier input supply busbars (top of Q1) and tighten the connectionsto 5,4 Nm – ensure correct phase rotation.

Bypass mains supply cables

3. If the installation does not include the provision of a separate bypass supplythen:

a) Ensure that the ‘split bypass’ links are fitted between the input mains bus-bars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) – seeFigure 2-5.

b) Ensure that the input supply neutral is connected to N3.

c) Jump to step 5.

4. If the installation does include the provision of a separate bypass supply then:

a) Connect the bypass supply cables between the bypass mains distribution

Sheathed cables clipped direct to or

lying on a non-metallic surface

2-6 s2-c1.fm5 - Issue 2 Dated 21/08/97


panel and the bypass supply busbars (junction of Q2/Q3) – see Figure 2-5.– ensure correct phase rotation.

b) Ensure that the bypass supply neutral is connected to N3

c) Tighten the connections to 5,4 Nm.

d) Remove the ‘split bypass’ links are (if fitted) between the input mains bus-bars (top of Q1) and the bypass supply busbars (junction of Q2/Q3) – seeFigure 2-5.

Figure 2-4: UPS External Cables

A

B

C

D

EF

G

H

A Rectifier a.c. input supply E Battery control/temp. compensation

B Bypass a.c. input supply F Communications to PC or modem

C UPS a.c. output G Communications to AS400/external alarms

D Battery power H Remote emergency power off (EPO)

s2-c1.fm5 - Issue 2 Dated 21/08/97 2-7


Figure 2-5: Power and control cable connections

Reset button

SafetyEarth

Auxiliary terminal block (X3)Terminals are male type spade connectors

Batt.

Tem

p

Com

mon

Batt

CB

aux.

conta

ct

Ba

tt C

B trip E.P.O.

K1

F13

F13

R S T N

R S T N

R S T N

R S S T

F11

F12

1 2 3 4 5 6 7 8 9 10 11 12

All power connections require lug type terminations.Connections torque loading is 5,4Nm

These links must be removed for split bypasssystems

UPS Rectifier (input mains)connections(from mains a.c. supply)

Input connections forsplit bypass system(from mains a.c. supply)

OutputConnections(to Load)

Bypass input supply neutral (split bypass system) ORInput supply neutral (non-split bypass)

2-8 s2-c1.fm5 - Issue 2 Dated 21/08/97


5. Connect the UPS output cables between the output busbars (junction Q3&Q4) and the load distribution panel, and tighten the connections to 5,4 Nm.

6. Connect the battery power cables between the UPS battery terminals and theassociated battery circuit breaker - see Figure 2-5 and Figure 2-7 - observethe correct battery cable polarity. As a safety precaution remove the batteryfuse in the module until the arrival of the commissioning engineer.

WARNING Do not close the battery circuit breaker before the equipment is commissioned.

7. Connect the safety earth and any necessary bonding earth cables to the copperearth busbar located below the battery power connections.Note: The earthing and neutral bonding arrangement must be in accordancewith local and national codes of practice.

8. Connect the battery circuit breaker control and temperature compensationcables between the UPS auxiliary terminal block ‘X3’ and battery circuitbreaker controller board as shown in Figure 2-5 and Figure 2-7. These cablemust be shielded.

Caution If battery temperature compensation is not to be used, it must be de-activated bythe commissioning engineer.

9. If the remote emergency power off (EPO) facility is to be used then removethe link between terminals 10 and 11 of the auxiliary terminal block ‘X3’ andconnect the ‘normally closed’ remote stop switch between these two termi-nals using shielded cable.

s2-c1.fm5 - Issue 2 Dated 21/08/97 2-9


1.4 Battery Installation

SAFETYWARNINGS

Only qualified personnel should install or service batteries.Batteries present a risk of electric shock or burn from high short circuit currents.Eye protection should be worn to prevent injury from accidental electrical arcs.Remove rings, watches and all metal objects. Only use tools with insulated handles.Wear rubber gloves.If a battery leaks electrolyte, or is otherwise physically dam-aged, it should be placed in a container resistant to sulphuric acid and disposedof in accordance with local regulations.If electrolyte comes into contact with the skin the affected area should be washedimmediately.Batteries must be disposed of according to local environmental laws.

Due to the IGBT inverter design, the required DC busbar voltage level is depend-ent on the system output a.c. voltage; the required number of battery blocks there-fore differ according to the system voltage, as shown below:-

380V a.c. system requires a 432V DC busbar = 192 battery cells.400V a.c. system requires a 446V DC busbar = 198 battery cells.415V a.c. system requires a 459V DC busbar = 204 battery cells.

The batteries associated with the UPS equipment are usually contained in a pur-pose-built battery cabinet which sits alongside the main UPS equipment. Sealed,maintenance-free batteries are normally used in this type of installation.

There are three types of battery cabinet offered with the Series 7200 UPS whichare graded according to their recommended ampere hour capacity. Type B is ratedat 38 Ah; Type C is rated at 50 Ah and Type D is rated at 85 Ah. The cabinets areof the same height as the UPS and can be sited on either side of the UPS cabinet.A full description of these cabinets is given in the Options Section of this manual.

Where battery racks are used, they should be sited and assembled in accordancewith the battery manufacturer's recommendations. In general, batteries require awell ventilated, clean and dry environment at reasonable temperatures to obtainefficient battery operation.

Battery manufacturers’ literature provides detailed safety measures to be ob-served when employing large battery banks: these should be studied, and the pro-posed battery installation checked, to verify compliance with the appropriaterecommendations.

In general a minimum space of 10 mm must be left on all vertical sides of the bat-tery block. A minimum clearance of 20 mm should be allowed between the cellsurface and any walls. A clearance of 150 mm should be allowed between the topof the cells and the underside of the shelf above (this is necessary to for monitor-ing and servicing the cells). All metal racks and cabinets must be earthed. All livecell connections must be shrouded.

The batteries are connected to the UPS through a circuit breaker which is manu-ally closed and electronically tripped via the UPS control circuitry. If the batteriesare cabinet-mounted this circuit breaker is fitted within the cabinet; however, ifthe batteries are rack-mounted or otherwise located remote from the main UPScabinet then the battery circuit breaker must be mounted as near as possible to thebatteries themselves, and the power and control cables connected to the UPSusing the most direct route possible. Liebert offer a purpose-designed remote bat-

2-10 s2-c1.fm5 - Issue 2 Dated 21/08/97


tery circuit breaker box, containing the circuit breaker and its necessary controlboard, as a standard option kit. The battery cabinet or circuit breaker box shouldbe bonded to the UPS cabinet to maintain EMC compliance.

1.4.1 Battery circuit breaker boxes

A battery circuit breaker box houses the battery circuit breaker and its controllerboard and is used to connect the battery to the UPS in installations where the bat-teries are not contained in the standard battery cabinet.

Two boxes are available which are similar in design and content, and describedbelow:

• 100 Amp C/B Part No. 4641027 B for use with 30 - 40 kVA models.• 160 Amp C/B Part No. 4641028 C for use with 60kVA model.

Usually the ‘box' is fitted as close as possible to the batteries. Battery circuitbreaker boxes must be earthed. The connections are similar to the connectionsmade to the battery cabinet.

Figure 2-6 shows details of the power and control cable connections between thecircuit breaker box or battery cabinet and the UPS itself. Two methods of connect-ing the three pole battery circuit breaker are illustrated. Method A shows the sparepole being used to divide the battery bank in half, thereby reducing the batterytotal voltage to half when the circuit breaker is open during servicing etc. MethodB connects the spare pole in series with the positive connection, thereby providingtwo sets of contacts in the positive line as an added safety precaution.

When installing the battery cabinet remove the battery fuse in the UPS beforemaking the battery circuit breaker power connections.

Figure 2-6: Battery CB layout of switching poles

UPS

UPS

Half Potential Switching Method

Double Positive Pole Method

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Figure 2-7: Battery Control and Power connections

TO BATTERIES

UPS CABINET

X3

1 2 3 4 5 6 12

D1

D2

1411

BATTERY CIRCUIT

BREAKER

X4X3X5X6

X8X9

V <X2

X10

LM355A Sensor0835047F

1

HALF POTENTIAL SWITCHING METHOD

TO BATTERIES

UPS CABINET

X3

1 2 3 4 5 6 12

D1

D2

1411

BATTERY CIRCUIT

BREAKER

X4X3X5X6

X8X9

V <X2

X10

LM355A Sensor0835047F

DOUBLE POSITIVE POLE METHOD

Battery CBController

Battery CBController

2 3 4 5

1 2 3 4 5

2-12 s2-c1.fm5 - Issue 2 Dated 21/08/97

Section 2:

Chapter 2 - Commissioning Procedure

2.1 Introduction

The information contained in this calibration procedure is intended for use onlyby engineers employed by the Liebert service organisation or who have attendeda training course concerning the Series 7200 equipment. While every precautionhas been taken to ensure the accuracy of this information, Liebert assume no re-sponsibility and disclaim all liability for damages resulting from the use of thisinformation or any errors or omissions contained within.

This procedure aims at satisfying two functions: first it should enable a product-trained engineer to commission the equipment safely and correctly; second, itshould provide a recovery procedure to supplement the procedures contained inthe troubleshooting section of this manual – i.e. if the troubleshooting proceduresfail to identify/rectify a problem then this procedure provides the means of com-pletely recalibrating the UPS equipment.

WARNING NOTICESPlease read.

The UPS equipment contains POTENTIALLY LETHAL VOLTAGES at all timesonce power has been applied from the MAINS DISTRIBUTION PANEL.Therefore, before applying mains power to the UPS ensure that the UPS outputcables are safely isolated or, If they have already been connected to the loadequipment, ensure the load equipment is ready to receive power.

DO NOT close the battery circuit breaker before instructed to do so. Closing thebattery circuit breaker before the DC busbar is live could damage the UPS.

DO NOT apply BOOST CHARGE to sealed batteries.

Before commencing this procedure confirm the location and operation of the ex-ternal power isolators used to switch the UPS input mains supply. If these isola-tors cannot be LOCKED OUT, then post notices warning against their closure.These precautions should be taken as necessary at any time during the commis-sioning procedure.

The 7200 Series UPS leaves the manufacturer fully tested and adjusted to operateat 400Vac, 50Hz, but it can be converted to operate at 380V or 415V, at either 50or 60Hz. Such a conversion is effected by selecting the appropriate tap voltageson the control power supply transformers and operating parameters via the Oper-ator Control Panel menuing system – details are provided at the appropriate stagesof this procedure. An additional procedure is included at the end of the chapter(See paragraph 2.10) which provides instructions for changing the working volt-age/frequency parameters on an already-commissioned module. In both cases,where reference is made to the ‘nominal’ voltage, this should be taken as the re-quired equipment working voltage – e.g. 380/400/415 volts.

A set of Commissioning Records are included at the end of this section which canbe used to record the parameters set during commissioning and handed to the cus-tomer if required. The pages are published in a single-sided format to facilitatephotocopying for in-field use.

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SECTION 2 - Installation and Commissioning 7200 Series UPS Service ManualCHAPTER 2 - Commissioning Procedure

1+11+1

Important Note: When commissioning a ‘1+1’ system we recommend that the system is split intotwo single modules; and each module then commissioned independent of theother. Once both modules are fully working as ‘single modules’ they can bereconfigured for ‘1+1’ operation and the remaining ‘parallel control’ functionschecked and calibrated as instructed.This commissioning procedure is therefore based on a ‘single-module’ installa-tion, and any actions which specifically apply to ‘1+1’ systems are identified bya “1+1” graphic in the margin – as shown here.Note: if you are converting an early (pre Jan ‘97) single module to operate in a‘1+1’ system then ensure the appropriate control boards are fitted prior to com-mencing the commissioning (See Chapter 3). (Later models are shipped with theappropriate boards already fitted).

2.2 Procedure overview

This procedure has several defineable stages:

1. Pre-commissioning checks verify that:– the main equipment has been correctly installed– the circuit board configuration links have been selected correctly – the battery installation is satisfactory– the control power transformers are wired for the required working voltage

2. Start-up and software commissioning:– low voltage supply checks– Operator Control Panel language selection– UPS Setup parameters selection (from Operator Control Panel)– UPS Maintenance parameters selection (from Operator Control Panel)– UPS Function parameters selection (from Operator Control Panel)

3. UPS Power checks:– UPS Power measurements– inverter checks– bypass checks– rectifier and battery autonomy checks– programming automatic battery check parameters– emergency power off (emergency stop) checks– battery boost set-up (if applicable)– on generator checks (if applicable)

2-14 s2-c2a.fm5 - Issue 3 Dated 09/11/98

7200 Series UPS Service Manual SECTION 2 - Installation and CommissioningCHAPTER 2 - Commissioning Procedure

Figure 2-8: Major component location

1

2

3

4

8

7

5

9

10

11

12

13

6

14

4550007H45

300

25T

X1

X2X3

4520075B

15

Table 2-2:

1. Battery Cable Connections 9. AC - AC Power Supply PCB 4503030M

2. UPS Output Cable Connections 10. Rectifier Logic PCB 4520074A

3. Static Bypass Input Cable Connections 11. Inverter Logic PCB 4530025T

4. Rectifier Input Cable Connections 12. UPS Logic PCB 4550007H

5. Main Chassis Safety Earth Connection 13. Remote Alarm Interface 4590056Q

6. Auxiliary Terminal Block X3 14. UPS Serial Number Tag

7. Control Power Transformers T2 & T3 15. 1+1 Parallel Option 4645004A (consisting of Parallel Logic Board 4520075B & ribbon cables)8. DC - DC Power Supply 4503028K



2.3 Pre-commissioning Checks

WARNING Ensure these checks are carried out before applying power to the unit.

2.3.1 Power cable installation

1. Verify that the input, output and battery cables are suitably rated, in accord-ance with local regulations – see notes on cable rating in paragraph 1.3.2.

2. Check that the power cables entering the UPS have been correctly routed andthe appropriate gland has been fitted to the power cable entry panel.

3. Check that the power cables are correctly terminated and securely fitted to thestepped input and output busbar studs as shown in Figure 2-9.

4. Check that the bypass links have been removed if the unit is to be operated inthe ‘Split Bypass’ configuration. If a separate supply is connected to thebypass terminals without the “split bypass” links removed it could causedamage to the supply distribution system.

1+11+1

Important Note: 5. In a ‘1+1’ system ensure that the paralleled module output cables are con-nected with the correct phasing (i.e. U2-U2; V2-V2; W2-W2; N2-N2).

Figure 2-9: Power cable connectionsBypass LinksThese links must be removed for split-bypass operation

Output Cables connected to load

Input cables for split-bypass systemConnected to Q2/Q3 busbar connection U3, V3, W3 & N3From Bypass Supply distribution panel

Bypass Supply Neutral connection (split-bypass system)ORInput Supply Neutral connection (non-split-bypass system)

UPS rectifier input connection from input mains supply:

For non-split-bypass system:a) Connect to Q1 busbar connections U1,V1,W1.b) Connect input neutral to Q2/Q3 busbar connection N3.

Note: an input neutral connection to N3 is not required in a split-bypass system as the bypass neutral will be used to reference the inverter output.

BatteryCables



2.3.2 Control cable installation

1. Verify that the battery control cables are correctly terminated and connectedto the auxiliary terminal block (X3) shown in Figure 2-10 in accordance withTable 2-3.Note: terminal block X3 requires 4mm (yellow) female spade terminations.

Figure 2-10: Auxiliary terminal block X3

Table 2-3: Auxiliary terminal block connections

UPS Auxiliary Terminal block

X3 Termination

FunctionBattery Control Board (4520067T) termination

X3 - 2 Battery temperature sense signal

X1 - 5

X3 - 3 X1 - 4

X3 - 4 Battery circuit breaker control common

X1 - 3

X3 - 5 Battery circuit breaker status signal

X1 - 2

X3 - 6 Battery circuit breaker trip signal

X1 - 1

X3 - 10 Remote Emergency Stop normally closed

Terminals normally linked if not usedX3 - 11

Battery Temperature

E.P.O.Batt CB trip

Batt CB Aux contact

Common



1+11+1

Important Note: 2. In a ‘1+1’ system:

a) Ensure that the Parallel Logic Board Part Nº 4520075B is firmly fitted inthe correct location as shown in Figure 2-8.

b) Ensure that the 60 way ribbon cable is connected from X1 on the ParallelLogic Board, to X7 on the UPS Logic Board.

c) Ensure that the two 34-way ribbon cables providing inter module controlare fitted between the Parallel Logic Board connector X2 of one moduleand X3 in the second module (See Figure 2-11). Note that it is crucial thatthese cables are cross-coupled between X2/X3 as shown. Failure toobserve this rule will result in the modules being permanently shut down.

Figure 2-11: Module parallel logic PCB interconnection

X3

X2

4520075B

X3

X2

4520075B��

��

Module 1 Module 2



2.3.3 Battery Power Cable Installation

1. Verify that the battery has been correctly installed and all cables are con-nected to the batteries and battery circuit breaker as shown in the installationinstructions (see paragraph 1.4 on page 2-10). Typical connection configura-tions are shown in Figure 2-12.

2. Verify that the battery power cables are correctly terminated and securely fit-ted to the DC busbar studs as shown in Figure 2-9.

Figure 2-12: Battery control and power connections

To Batteries

To Batteries

Temperature Sensor

Temperature Sensor

Battery Circuit Breaker

Battery Circuit Breaker

Battery C.B. Controller PCB Part

Nº 4520067T

X3

X3

Half Potential Switching Method of Connection

Double Positive Pole Method of Connection



2.3.4 Printed circuit board configuration jumper selection

Ensure that the printed circuit board jumpers are selected appropriately accordingto the following tables:

Table 2-4: Rectifier Logic Board – 4520074A. 30 to 60kVA

JUMPER POSITION FUNCTION

X5 1 - 2

Disable battery temperature/voltage compensation (Standard)

2 - 3 Enable battery temperature/voltage compensation

X6 1 - 2 Increased DC regulation speed for units below 60kVA

2 - 3 Decreased DC regulation speed for units above 80kVA

X7 1 - 2 Fast walk-in : 1 Second

2 - 3 Slow walk-in : 5 Seconds

X9

0 - 1 openRectifier in Auto mode (Standard)

0 - 2 open

0 - 1 closedRectifier in Float mode

Set Rectifier to Manual Mode from the Dis-play Panel

0 - 2 open

0 - 1 openRectifier in Boost mode

0 - 2 closed

0 - 1 closedRectifier in ‘Test’ mode

0 - 2 closed

0 - 3closed Reduced input current limit forced on

open (Standard)

0 - 4closed Rectifier forced on - Ignore UPS Logic

open UPS Logic control enabled (Standard)

0 - 5open Disable driver IC - D6

closed Enable driver IC - D6 (Standard)

X101 - 2 Enable rectifier temperature monitor

2 - 3 Disable rectifier temperature monitor (Standard)



Table 2-5: Inverter Logic Board 4530025T. 30 - 60kVA

Table 2-6: UPS Logic Board 4550007H. 30 - 60kVANote: when commissioning a ‘1+1’ system these jumpers will required temporaryreconfiguration (See paragraph 2.3.5.1)


X12

0 - 1 openTest Inverter over-temperature sensors (Enables open cct. sen-sors)

0 - 1 closed Disable Inverter over-temperature sensors (Standard)

0 - 2 open Enable ribbon cable detector (Standard)

0 - 2 closed Disable ribbon cable detector

0 - 3closed

Voltage select override

Manual inverter volts Adj R243

Testing onlyOpen = standard

0 - 4

0 - 5 Frequency select override

0 - 6 Force the Inverter ON => ignore all blocks

0 - 7 Ignore Inverter ‘On Load’ signal

X15

0 - 1 2400 Hz switching frequency (Standard)

0 - 2 4800 Hz switching frequency

0 - 10 - 2

9600 Hz switching frequency

0 - 5 1200 Hz switching frequency

X16

0 - 10 - 2

6 pulse Inverter current feedback (Standard)

0 - 3 12 pulse Inverter current feedback


X12

open Pre- Release Rev.:5.0G Software

1 - 2 Link if Rev.:5.0G or later and HVI PCB Part Nº 5490054O is fitted.

3 - 4Link if Rev.:5.0G 0r later and HVI PCB Part Nº 5490058S is fitted.

X13 1 - 2 EPROM Enable

2 - 3 RAM Enable (Standard)

X14

1 - 2 Not Required

Testing onlynormally open

3 - 4 Not Required

5 - 6 Not Required

7 - 8 Not Required



X151 - 2 PLL option with

2 - 3 PLL option with (Standard)

X16open CAN Bus to display disabled

1 - 2 CAN Bus to display enabled (Standard)

X171 - 2 ALE enable data save

2 - 3 Power supply fail enable data save (Standard)

X191 - 2 EPROM II enable (not required)

2 - 3 RAM II enable (not required)

X20

1 - 2+5V PCB enables microprocessor ref. For VA calculations (Standard)

2 - 3V ref. enables microprocessor ref. For VA calculations

X211 - 2 Not Required

2 - 3 RAM enable (Standard)

X221 - 2 EPROM enable (Standard)

2 - 3 Not Required

X23

1 - 2 Not Required

2 - 3 EPROM enable (Standard)

3 - 4 Not Required

4 - 5 Not Required

X24


2 - 3 EPROM enable (not required)


4 - 5 EPROM enable (not required)

X251 - 2 Manual reset of output buffers

2 - 3 Microprocessor reset of output buffers (Standard)

X26

1 - 2

Inverter operation in ‘Manual’ mode (Bypass preferred) = ClosedInverter operation in ‘Auto’ mode (Inverter Preferred) = Open (Standard)

3 - 4Inverter Bad voltage for 10 secondsOff latch enabled = Closed (Standard)Off latch disabled = Open

5 - 6 Not Required

7 - 8Security Password Over-ride. Closed = Over-ride security Password Open = Enable security Password (standard)


CAP IN

FIN AUX



Table 2-7: Operator Control Board 4550005F 30-60 kVA

X28open Power up reset enabled (Standard)

closed Power up reset disabled

X29open 2.5V power supply monitor enabled (Standard)

1 - 2 2.5V power supply monitor disabled

X31open Internal battery disabled

1 - 2 Internal battery installed and charger enabled (Standard)

X32open RS485 port disabled

1 - 2 RS485 port enabled (Standard)

X331 - 2 Calendar IC supply from VRAM (Standard)

2 - 3 Calendar IC supply from internal battery

X341 - 2 G.V.C.O. to inverter logic (parallel module operation)

2 - 3 Micro V.C.O. to inverter logic (single module operation)

X351 - 2 Separate battery per module (1 for each rectifier)

2 - 3 Common battery (parallel rectifiers)





X11open +5v enable main CPU (Standard)

closed ALE enable main CPU

X12 1 - 2 Main CPU enable EPROM

2 - 3 +5v enable EPROM (Standard)

X13 1 - 2 Main CPU enable RAM

2 - 3 +5v enable RAM (Standard)

X14 1 - 2 Not Required Testing Only

Open = Standard2 - 3 Not Required

X151 - 2 Main CPU enable EPROM (Standard)

2 - 3 Not Required



x16

1 - 2 Not Required

2 - 3 Main CPU enable EPROM (Standard)

3 - 4 Not Required

4 - 5 Not Required

x17

1 - 2 Write to RAM enable (Standard)

2 - 3 Not Required

3 - 4 Main CPU enable RAM (Standard)

4 - 5 Not Required

X181 - 2 Not Required

2 - 3 Main CPU enable RAM (Standard)

x191 - 2 Not Required RAM extension

Normally open2 - 3 Not Required

x201 - 2 Read/Write RS232 enable (Standard)

2 - 3 Read/Write RS485enable

x211 - 2 Enable port x4 for RS485

2 - 3 Enable port x4 for RS232 (Standard)

x221 - 2 Enable port x4 for RS485

2 - 3 Enable port x4 for RS232 (Standard)

x231 - 2 Inhibit buzzer

2 - 3 Enable buzzer (Standard)

x241 - 2 Enable CAN bus to UPS logic (Standard)

2 - 3 Disable CAN bus to UPS logic

x251 - 2 Enable RS485 bus to port x4 (Standard)

2 - 3 Disable RS485 bus to port x4

x26open +5v power supply reset enabled (Standard)

closed +5v power supply reset disabled




Table 2-8: Static Switch Driver Board 4542043Z 30-60 kVA

Table 2-9: High Voltage Interface Board 4590058S & (old 4590054O) 30-60kVA


X11

0 - 1 openEnable load on inverter command (Standard)

0 - 1 closed Disable load on inverter command

0 - 2 openEnable load on bypass command (Standard)

0 - 2 closed Disable load on bypass command

0 - 3 open Disables bypass fire command

0 - 3 closed Enable bypass fire command (Standard)

0 - 4 N/A Not used

0 - 5 open Test static switch temperature monitor

0 - 5 closedInhibit static switch temperature monitor (Standard)


— 0 - 1

30 kVA CT burden selec-tion

X31 0 - 2

X31 : X32 : X33 : X34 : X35 : X37 : X38 : X39 : X40

0 - 3

— 0 - 140 kVA CT burden selec-tion

X31 : X32 : X33 : X34 0 - 2

X35 : X36 : X37 : X38 : X39 : X40 0 - 3

— 0 - 1

60 kVA CT burden selec-tion

— 0 - 2

X31: X32 : X33 : X34 : X35 : X36 : X37 : X38 : X39 : X40

0 - 3



1+11+1

Applicable only to: Table 2-10: Parallel Logic Board 4520075B

2.3.5 Pre-power checks

1. Ensure that all the UPS isolators, including the battery circuit breaker, areopen – i.e. OFF or in position ‘0’.

2. Carry out a thorough visual examination of the equipment. Check the securityof all cable terminations and ensure that all electrical connectors, plugs andsockets are correctly located and firmly fitted.

3. Ensure that the correct primary voltage tap selections are made on the PowerSupply transformers T2 and T3, as shown below.


X4

0 - 1open Priority selector disabled

closed Priority selector enabled (standard 1+1)

0 - 2to

0 - 8

open Priority selector for ≥ 2 modules (multi module use only) open = standard for 1+1

X5 0 - 1

to0 - 5

open closed

Link combination sets logic for number of units operatingFor 1+1 operation links 0 - 1, 0 - 2, 0 - 3 are closed.

X6

0 - 1 open 1 + 1 redundant module (standard)

closed 1 + 1 non-redundant module

0 - 2open Common battery for all UPS modules

closed Separate battery for each module (std)

0 - 3open Priority selector enabled (std)

closed Priority selector disabled

0 - 4open No MSSC installed (1 + 1) (std)

closed MSSC installed

0 - 5 N/A

0 - 6 N/A

0 - 7open No contactor in MSSC (std)

closed Contactor in MSSC

0 - 8open Normal operation

closed Test mode active

X71 - 2 60 Hz operation

2 - 3 50 Hz operation (std)

X11open G.V.C.O. slew rate = 0.1 Hz/Sec (std)

closed G.V.C.O. slew rate = 0.2 Hz/Sec

X131 - 2 Parallel cable screen earthed

2 - 3 Parallel cable screen not earthed (std)



Table 2-11: Power supply transformers T2 and T3 voltage selection.

4. Ensure that on the UPS Logic Board (4550007H):

a) S1 is selected OFF (Static Bypass disabled).

b) S2 is selected OFF (Inverter disabled).

c) S3 is selected OFF (Rectifier disabled).

2.3.5.1 ‘1+1’ system module split

1+11+1

Only applicable to: As mentioned at the beginning of this chapter, it is recommended that when deal-ing with a ‘1+1’ parallel-operating system each module is checked individuallyfor correct single module function before any attempt is made at parallel opera-tion. To satisfy this requirement the system must therefore be temporarily re-con-figured to allow single-module operation by completing the following steps:

1. Override the parallel control functions by disconnecting the ribbon cablebetween the Parallel Logic Board (4520075B) connector X7 and connectorX1 of the UPS Logic Board (4550007H).

2. Reconfigure the UPS Logic Board (4550007H) jumpers for single moduleoperation as shown in the table below – note that a complete link table forthis board is shown in Table 2-6.

Table 2-12: Temporary UPS Logic Board configuration changes.

X34 must be in position 2-3 for single module operation.X26 must be in position 7-8 to override the password security control.

WARNING These jumpers must be returned to the ‘1+1’ configuration before the system isoperated in parallel (as instructed later in the commissioning procedure).

380V Operation 400V Operation 415V Operation

A3 - B A2 - B A1 - B

X26

1 - 2 *Inverter operation in ‘Auto’ mode (Open = Standard)

3 - 4Inverter Bad voltage for 10 seconds*Off latch enabled = Closed (Standard)Off latch disabled = Open

5 - 6 Not Required

7 - 8Security Password Override. *Closed = Override security Password Open = Enable security Password (standard)

X341 - 2 G.V.C.O. to inverter logic (parallel module operation)

2 - 3 *Micro V.C.O. to inverter logic (single module operation)

X351 - 2 *Separate battery per module (1 for each rectifier)


X361 - 2 *Separate battery per module (1 for each rectifier)




2.3.6 Initial utility power connection

WARNINGS Check that the Maintenance Bypass isolator Q3 is open before applying externalpower. If Q3 is to be closed, inform the user that power will be connected to theload when the input utility isolator is made.

When commissioning a ‘1+1’ system module do not close any power isolators inthe second module while the module being commissioned is turned on.

1. Apply mains voltage to the input terminals – U1, V1and W1.

a) Measure the line-to-line voltage of all three phases and ensure that the val-ues are within ±10% of nominal rating.

b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope orrotation meter.

WARNING If a separate supply is connected to the bypass terminals without the “split by-pass” links removed it could cause damage to the supply distribution system.

2. If a split bypass is fitted, first ensure that the Split Bypass links have beenremoved (See Figure 2-9) then energise the (bypass) mains voltage to thebypass terminals – U3, V3, W3 and N.

a) Measure the line-to-line and line-to-neutral voltages of all three phasesand ensure that values are within ±10% of nominal rating.

b) Ensure correct clockwise phase rotation U, V, W using an oscilloscope orphase rotation meter.


7200 Series UPS Service Manual SECTION 2 - Installation & CommissioningCHAPTER 2 - Commissioning Procedure

Section 2:

2.4 Start-Up and software commissioning

During this part of the commissioning procedure, the bypass supply is connectedto the unit in order to power-up the control power supplies. With control poweravailable, the control circuit boards are live and the programmable UPS operatingparameters can be entered into control system’s non-volatile RAM (NVRAM) viathe Operator Control Panel, before energising the UPS power sections.

2.4.1 Operator Control Panel display screen

The LCD screen can display four rows of up to twenty characters, and normallyindicates the UPS operating status, warnings and alarms. However, it can also beselected to show messages associated with the UPS configuration setup menuingsystem which allows operational data to be entered, or control parameters to beset – these menus are shown in Figure 2-14 to Figure 2-27.

Figure 2-13: LCD control screen & selection buttons

When selecting an option, pressing the ENTER button steps forward to the next LCD Display screen in the menu map.When entering data or selecting a parameter, pressing the ENTER button saves the chosen parameter in non-volatile memory.

Pressing ESCAPE will cancel the most recent action – i.e. when entering data or selecting parameters, pressing ESC steps back the LCD display to the previous screen and exits the current screen without saving the new settings. To return to the default screen ESC must be pressed repeatedly.

The MENU buttons allow the window cursor to be moved up and down to select a desired menu option.UPThe UP button moves the cursor up through the options displayed in the window; the highlighted option can then be selected by pressing ENTER. When selecting a parameter value it also moves a rectangular “entry” cursor horizontally to the next digit on the right.DOWNThe DOWN button moves the cursor down through the options displayed in the window, the highlighted option can then be selected by pressing ENTER. When changing a parameter value the DOWN button will rotate through an available value table for the specific parameter digit.

ENTER

ESCAPE

s2-c2b.fm5 - Issue 3 Dated 09/11/98 2-29

SECTION 2 - Installation & Commissioning 7200 Series UPS Service ManualCHAPTER 2 - Commissioning Procedure

Important Note: This procedure refers to Version 4.0 software installed in all units manufacturedafter 2nd May 1997. Units manufactured before this date may have Version 2.0,or earlier, software installed and will exhibit slightly different menu screens andparameter locations.

2.4.2 Applying power to the UPS

WARNING Do not close the Output Isolator Q4 during the setting-up procedure as this willconnect power to the load.

1. Close the Bypass Isolator Q2.

a) The power supply and electronics will energise.

b) The Operator Control Panel display will power up.

c) The rectifier and inverter power sections will remain off.

2. On the Operator Control Panel, verify that the bypass LED and amber batteryisolator LED are illuminated.

3. Verify that the LCD control screen initialising window activates and thenchanges to the ‘Default’ screen. Note: the screen shown below is referred to as the default screen in theremainder of this procedure.

The module status alarms are initially displayed on the default screen in thedefault language, e.g. Italian.Note: The first three lines of the default screen will indicate any current UPS alarm conditions, but these can be ignored at this stage.

2.4.3 Password protection and operation

A password is required to change parameters other than those listed below:

• Time and Calendar• ON/OFF UPS CONTROL (rectifier, inverter and bypass)• Battery test (star, time/date stamp, repetition rate)• Modem configuration and operation

You can completely override the password system during initial start-up and com-missioning by connecting a link to jumper X26 pins 7-8 on the UPS Logic Board.This link, which must be removed when commissioning is completed, can befitted while the UPS is in its Normal Operation mode without affecting the systemintegrity.

Note: any parameter not re-programmed during the commissioning procedurewill maintain its factory default setting.

OUTPUT BREAKER OPEN

RECTIFIER BREAKER OPEN

BYPASS INHIBIT

24-09-95 14:33:00

INT USCITA APPERTO

INT RADDRIZZ APERTO

BATTERIA PINE SCAR

24-09-95 14:33:00

DEFAULT SCREEN

2-30 s2-c2b.fm5 - Issue 3 Dated 09/11/98


2.4.4 Language Selection

If required, select the appropriate language using the following procedure:

Figure 2-14: Language selection menu map

1. Ensure a jumper link is fitted to X26 pins 7-8 on the UPS Logic Board (over-rides the password protection facility as described previously).

2. Press the ‘ENTER’ button to access the main menu screen.

3. Press the ‘DOWN’ menu button to scroll the cursor to ‘FUNCTION’.

4. Press the ‘ENTER’ button to access the password entry screen.

5. A password must be entered to gain further access to the function menu. Theinitial default password of ‘00000000’ need not be changed at this point in time– instructions for changing the password are given later. (See paragraph2.4.7.4) .

6. Press the ‘ENTER’ button to move from the password entry screen to the func-tion menu screen.

7. Press the ‘DOWN’ menu button to select ‘PANEL SETUP’.

8. Press ‘ENTER’ to display the panel setup menu screen.

MAIN MENU SCREEN

FUNCTION MENU SCREEN

PANEL SETUP MENU SCREEN

MEASUREMENT

→ FUNCTION ←MAINTENANCE

SETUP

→ MISURE ←FUNZIONI

MANUTENZIONE

IMPOSTAZIONE

MAIN MENU SCREEN

↑ WRITE SAVE ↵↓ MOVE EXIT ESC

INPUT PASSWORD

0 0 0 0 0 0 0 0

↑ IMPOSTA MEMOR. ↵↓ SPOSTA USCITA ESC

DIGITARE PASSWORD

0 0 0 0 0 0 0 0

PASSWORDSCREEN

BATTERY TEST

GENERATOR

→ PANEL SETUP ←NEXT PAGE

→ TEST BATTERIA ←GRUPPO ELETTR.

DATI PANNELIO

PAGINE SUCCESSIVE

FUNCTION MENUSCREEN



9. On the panel setup menu move the cursor to select ‘LANGUAGE’.

10.Press ‘ENTER’ to display the language selection screen.

11.Use the ‘UP’ menu button to rotate through the available options and selectthe required default language – e.g. ‘ITA, ENG, FRA, DEU, SPA’

12.Press ‘ENTER’ to accept and store the language selection, then step back to thedefault screen by repeatedly pressing ‘ESC’, as required; the current alarmsshould now be displayed in the selected language.

IMPORTANT Ensure the data entered during the following procedures are recorded in the appropriate commissioning documentation.

→ LANGUAGE ENG ←TYPE 0000 MASTER

GROUP 1 UPS 1

PASSWORD 00000000

→ LINGUA ITA ←TIPO 0001 MASTER

GROPPO 1 UPS 1

PASSWORD 00000000

PANEL SETUPMENU SCREEN

↑ ROTATE SAVE ↵EXIT ESC

LANGUAGE ENG

↑ MEMOR. ↵USCITA ESC

LINGUA ITA

LANGUAGE SELECTION

SCREEN



2.4.5 Selecting the UPS SETUP parameters

The following procedure set-up the basic UPS operating parameters – e.g. kVA,working voltage/frequency and battery parameters.

Menu selection is carried out in the same manner as previously described in the‘language selection’ procedure – i.e. by first selecting a menu option using the ‘UP’

and ‘DOWN’ menu buttons and then accepting the selection by pressing the ‘ENTER’

button. In the remaining procedures these two actions are jointly summarized as‘select and enter’.

Figure 2-15: UPS system ‘SETUP’ menu map (Issue 5.0 software)

Continued in Figure 2-16

SETUP MENU SCREEN

MAIN MENU SCREEN

UPS MENU SCREEN

VOLTAGEMENU

SCREEN

FREQUENCYMENU

SCREEN

BATTERYMENU

SCREEN



1. From the default screen press ‘ENTER’ to access the main menu screen.

2. Select and enter ‘SETUP’ – the password screen will now be shown.

3. If the password has been left at the initial default setting, pressing ‘ENTER’will now step forward to the setup menu screen, as shown in Figure 2-15. Ifthe password has been “set”, then enter the correct password to continue.

2.4.5.1 Setting the basic UPS configuration

1. Select and enter ‘UPS’ – this will access the UPS menu screen.

2. Select and enter ‘POWER’.

3. Enter the UPS module’s kVA rating using the data entry screen shown below.

a) Pressing the ‘DOWN’ menu button will move the cursor to select each digitin turn: the value of the selected digit can then be incremented by pressingthe ‘UP’ menu button.

b) When the indicated kVA rating is correct, press ‘ENTER’ to save the selec-tion, then press ‘ESC’ once to move back to the UPS menu screen.

4. Select and enter ‘TYPE’.

a) Press the ‘UP’ menu button repeatedly until the ‘TYPE’ is shown as ‘3PH’.

b) Press ‘ENTER’ to save the selection, then press ‘ESC’ once to move back tothe UPS menu screen.

5. Select and enter ‘CONFIG’.

1+11+1

a) Using the data entry method described above enter the word ‘SINGLE’.(Note: in a ‘1+1’ installation this will be changed to ‘PAR 1+1’ later).

b) Press ‘ENTER’ to save the selection, then press ‘ESC’ to move back to theUPS menu screen.

6. Verify that the UPS menu screen data shows the correct: – UPS kVA rating (shown as 60kVA in the example screen in Figure 2-15)– UPS type (3 phase)– UPS configuration (single)Repeat this procedure if any data is incorrect.

7. Press ‘ESC’ again to move back to the setup menu screen.

2.4.5.2 Setting the UPS working voltage parameters

1. Select and enter ‘VOLTAGE’ – this will access the voltage menu screen.

2. Select and enter ‘RATED VOLTS.’.

a) Press the ‘UP’ menu button repeatedly until the appropriate input/outputworking voltage is indicated.

b) Press ‘ENTER’ to save the selection and then press ‘ESC’ once to move backto the voltage menu screen.

↑ WRITE SAVE ↵↓ MOVE EXIT ESC

POWER 0060 kVA



3. Select and enter ‘LOWER’.

a) Using the data entry method described above, enter the required input andoutput voltage undervoltage thresholds.Note: Standard settings are for -10% (input) and -10% (output).

b) Press ‘ENTER’ to save the selection, then press ‘ESC’ once to move back tothe voltage menu screen.

4. Select and enter ‘UPPER’.

a) Using the data entry method described above, enter the required input andoutput overvoltage thresholds.Note: Standard settings are for +10% (input) and +10% (output).

b) Press ‘ENTER’ to save the selection, then press ‘ESC’ once to move back tothe voltage menu screen.

5. Verify that the data shown on the voltage menu screen is correct and repeatthis procedure if necessary.


2.4.5.3 Setting the UPS frequency parameters

1. Select and enter ‘FREQUENCY’ – this will access the frequency menu screen.

2. Select and enter ‘NOMINAL’.

a) Press the ‘UP’ menu button repeatedly until the desired nominal frequencyis indicated.

b) Press ‘ENTER’ to save the selection, then press ‘ESC’ once to move back tothe frequency menu screen.

3. Select and enter ‘SYNC WINDOW’.

a) Enter the required sync window limit.Note: Standard setting is ‘2.0%’.


4. Select and enter ‘SLEWRATE’.

a) Enter the required slew rate from the following selections.0.1 Hz/sec0.5 Hz/sec1.0 Hz/sec

Note: Standard setting is ‘0.10 Hz/s’.


5. Verify that the data shown on the frequency menu screen is correct and repeatthis procedure if necessary.




2.4.5.4 Setting the Battery parameters

Figure 2-16: ‘SETUP’ menu map continued for battery parameter (Issue 5 software)

1. From the setup menu select and enter ‘BATT.CELLS’ – this will access the bat-tery menu screen (illustrated in Figure 2-16).

Setting the number of cells:

2. From the battery menu screen, select and enter ‘BATT.CELLS’.

3. Following the data entry method described earlier, using the ‘UP’, ‘DOWN’menu buttons, enter the number of cells contained in the battery string.

4. Press ‘ENTER’ to save the data to memory, then press ‘ESC’ once to return tothe battery menu screen.

Setting the Battery Capacity:

5. From the battery menu screen, select and enter ‘CAPACITY’.

6. Using the ‘UP’, ‘DOWN’ menu buttons, enter the total battery A/Hr capacity (atthe 10Hr rate C10).

WRITE SAVEMOVE EXITBATT.CELLS 198

WRITE SAVEMOVE EXITCAPACITY 052 Ah

WRITE SAVEMOVE EXITEND DIS. 1.67 v/e

WRITE SAVEMOVE EXITBAT.LOW 1.82 v/e

WRITE SAVEMOVE EXITMAX. 2.45 v/e

UPS 0060 kVAVOLTAGE 400 VFREQUENCY 50 HzBATT.CELLS 198

BATT.CELLS 198CAPACITY 052 AhVOLTAGE/CELL



END DIS. 1.67 v/eBAT.LOW 1.82 v/eMAX. 2.45 v/eBOOST CHARGE





BATTERY VOLTAGEMENU SCREEN

SETUP MENU SCREEN

BATTERY MENU SCREEN

Continued from Figure 2-15




Setting the battery voltage characteristics:

8. From the battery menu screen, select and enter ‘VOLTAGE’ – this will take youto the battery voltage menu, which is concerned with selecting the batterycharging characteristics.

Battery undervoltage trip setting

9. From the battery voltage menu, select and enter ‘END DIS.’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘end-of-dis-charge’ voltage – standard setting is 1.67V/cell.Note: this is the ‘end-of-discharge’ voltage and is the voltage at which thebattery breaker is tripped.

b) Press ‘ENTER’ to save the data to memory, then press ‘ESC’ once to returnto the battery voltage menu screen.

Battery low voltage warning setting

10.From the battery voltage menu, select and enter ‘BAT LOW’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘low battery volt-age’ – standard setting is 1.82V/cell.Note: this is the voltage at which ‘low-battery warning’ annunciates.


Battery overvoltage trip setting

11.From the battery voltage menu, select and enter ‘MAX’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘max batteryvoltage’ – standard setting is 2.45V/cell. This sets the ‘slow’ overvoltagelevel which is effective only when the batteries are in the float chargemode, and is the voltage at which, after 3 minutes, the battery breaker istripped, and the rectifier and inverter turned OFF.


Battery boost charge values

WARNING DO NOT apply BOOST CHARGE to sealed batteries



Figure 2-17: Battery boost charge parameters

12.From the battery voltage menu, select and enter ‘BOOST CHARGE’ – this willtake you to the boost charge menu screen.

13.From the boost charge menu, select and enter ‘SETUP’ – this will take you tothe battery boost setup menu screen.

14.From the battery boost setup menu, select and enter ‘DURATION’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required boost operationtime (in minutes) – factory setting is 600 mins.

b) Press ‘ENTER’ to save the data to memory, then press ‘ESC’ once to returnto the battery boost setup menu screen.

15.From the battery boost setup menu, select and enter ‘THRESHOLD’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required current change-over threshold – factory setting is 20% of the battery current limit.Note: this is the level that the battery current must reach before boostcharge is enabled upon mains return.


16.It is advisable to set the ‘NOW’ and ‘AUTOMATIC’ parameters to ‘NO’ at thisstage in the commissioning, and reset to ‘YES’ (if required) once the rectifierhas been fully commissioned.

Verification:

17.Press ‘ENTER’ to save the data to memory, then press ‘ESC’ once to return tothe battery voltage menu screen.

18.Verify that the data shown on the battery voltage menu screen is correct andrepeat this procedure if necessary.

19.The setup menu parameters have now all been entered and stored in the con-trol system’s non-volatile memory. Press ‘ENTER’ repeatedly to return to thedefault menu

Continued fromFigure 2-16

BATTERY VOLTAGE MENU SCREEN

BATTERY BOOST MENU SCREEN

BATTERY BOOST SETUPMENU SCREEN



2.4.6 Selecting the UPS MAINTENANCE parameters

Figure 2-18: ‘MAINTENANCE’ menu map

The UPS serial number, service information, and current time and date are all en-tered via the maintenance menu map shown in Figure 2-18.

2.4.6.1 Accessing the maintenance menu


2. Select and enter ‘MAINTENANCE’ – the password screen will now be shown.

3. If the password has been left at the initial default setting, pressing ‘ENTER’will now step forward to the maintenance menu screen, shown in Figure 2-18.If the password has been “set”, then enter the correct password to continue.

2.4.6.2 Entering the Serial Number

1. From the maintenance menu screen, select and enter ‘S.N.’Note: The UPS serial number can be found stamped on a circular metal plateattached to the top of the unit, behind the left hand door.

2. Using the ‘UP’ and ‘DOWN’ menu buttons, enter the UPS serial number.

3. Press ‘ENTER’ to save the settings, then press ‘ESC’ once to return to the main-tenance menu screen.

MAINTENANCE MENU

MAIN MENU SCREEN DEFAULT SCREEN

SCREEN



2.4.6.3 Entering the current Date and Time

1. From the maintenance menu screen, select and enter the line showing thetime and date. (This may initially indicate all zeroes).

2. Using the ‘UP’ and ‘DOWN’ menu buttons, enter the current time and dateinformation.


2.4.6.4 Entering the Service details

1. From the maintenance menu screen, select and enter ‘LAST SER.’ to register thedate of the current service or commissioning.



4. Select and enter ‘NEXT SER.’ to record the date of the anticipated next service.



7. Verify that the data shown on the maintenance menu screen is correct andrepeat this procedure if necessary. Then press ‘ESC’ repeatedly to step back tothe default menu screen.

8. The maintenance menu parameters have now all been entered and stored inthe control system’s non-volatile memory.

2.4.7 Selecting the UPS FUNCTION parameters

The function menu screens, shown in Figure 2-19 and Figure 2-20, enable certainparameters to be set and also gives access to various software-initiated functionalchecks.

The procedures contained in this section are concerned with parameter setting; the‘functional checks’ facilities are used later in the commissioning procedure,during the power checks.

2.4.7.1 Accessing the function menu


2. Select and enter ‘FUNCTION’ – the password screen will now be shown – if thepassword has been left at the initial default setting, pressing ‘ENTER’ will nowstep forward to the main menu screen. If the password has been “set”, thenenter the correct password to continue.

3. From the main menu, select and enter ‘FUNCTION’ to access the function menuscreen.



Figure 2-19: ‘FUNCTION’ selection menu map(Issue 5 software


FUNCTION MENU

GENERATOR

BATTERY TEST MENU SCREEN

SCREEN

MENUSCREEN

PANELSETUPMENU

SCREEN

BATTERY TEST SETUPMENU SCREEN



4. From the default screen press ‘ENTER’ to display the option selection screen.

5. Select and enter ‘FUNCTION’.

6. The password screen will now be shown.

7. If the password has not yet been set, pressing ‘ENTER’ will step forward to themaintenance selection screen shown in Figure 2-19.

2.4.7.2 Setting the Battery Test parameters

1. From the function menu screen, select and enter ‘BATTERY TEST’ to access thebattery test menu.

2. Three selections are available: ‘NOW’, ‘AUTOMATIC’ and ‘SETUP’.

‘NOW’ Selection: When ‘NOW’ is set to ‘YES’, it initiates an immediate batterytest by switching off the UPS rectifier section. This is not required at this time butis used later in the commissioning during the “power checks”.

3. From the battery test menu, select and enter ‘NOW’.

4. Press ‘ENTER’ to step to the selection screen and, using the ‘UP’ menu button,select NO (‘N’).

5. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the battery testmenu screen.

‘AUTOMATIC’ Selection: ‘AUTOMATIC’ initiates a battery test cycle at a pre-defined set time and date (as entered in the setup selection menu below).

6. From the battery test menu, select and enter ‘AUTOMATIC’.

7. If an automatic battery test function is required, press ‘ENTER’ to step to theselection screen and, using the ‘UP’ menu button, select YES (‘Y’).

8. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the battery testmenu screen.

SETUP Selection: ‘SETUP’ allows the parameters to be set for the automatictesting cycle (see above).

9. From the battery test menu, select and enter ‘SETUP’ to access the battery testsetup menu screen.

10.From the battery test setup menu select and enter ‘DURATION’.

11.Using the ‘UP’ and ‘DOWN’ menu buttons, enter the test ‘DURATION’ time inminutes. (This would normally be set to 5 minutes).

12.Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the battery testsetup menu screen.

13.From the battery test setup menu select and enter ‘THRESHOLD’.

14.Using the ‘UP’ and ‘DOWN’ menu buttons, enter the minimum battery test volt-age ‘THRESHOLD’ level. (This would normally be set to 1.9V/Cell).

15.Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the battery testsetup menu screen.

16.From the battery test setup menu select and enter ‘PERIOD’.



17.Using the ‘UP’ and ‘DOWN’ menu buttons, enter the ‘PERIOD’ (in days) atwhich the test is to occur in days.(This would normally be set to 90 days).

18.Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the battery testsetup menu screen.Note: Once the first Automatic Battery test has been actioned, the time anddate will up-date according to the selected period. This will change on thedisplay to indicate when the next battery test will be carried out.

Verification:

19.Verify that the data shown on the battery test setup menu screen is correct andrepeat this procedure if necessary.

20.Step back to the battery test menu screen by pressing ‘ESC’.

21.Verify that the data shown on the battery test menu screen is correct andrepeat this procedure if necessary.

22.Step back to the function menu screen by pressing ‘ESC’.

2.4.7.3 Setting the Generator parameters

1. From the function menu screen, select and enter ‘GENERATOR’ to access thegenerator menu screen.

2. Three selections are available: ‘INV: SYNC INHIBIT’, ‘RECT: I INHIBIT’ and ‘BAT: I INHIBIT’.Note: These features require external control input via the Remote AlarmsBoard in order to become active.

INV: SYNC INHIBIT Selection: This disables synchronisation between theUPS and generator when the generator is on-line. When selected, it helps to over-come “Sync Error” problems occurring when running on a generator whose fre-quency is unstable.

3. From the generator menu screen, select and enter ‘INV: SYNC INHIBIT’.

4. Using the ‘UP’ menu button, set the attribute to YES ‘Y’ or NO ‘N’ as required.

5. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the generatormenu screen.

BAT: I INHIBIT Selection: This restricts the maximum charge current to thebatteries when the generator is on-line and is used if the generator power outputis limited.

6. From the generator menu screen, select and enter ‘BAT: I INHIBIT’.

7. Using the ‘UP’ menu button, set the attribute to YES ‘Y’ or NO ‘N’ as required.

8. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the generatormenu screen.

RECT: I INHIBIT Selection: This reduces the maximum UPS input currentby 30% of the standard factory-set current limit when the generator is on-line.This facility is used if the generator power output is limited.

9. From the generator menu screen, select and enter ‘RECT: I INHIBIT’.

10.Using the ‘UP’ menu button, set the attribute to YES ‘Y’ or NO ‘N’ as required.



11.Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the generatormenu screen.

Verification:

12.Verify that the data shown on the generator menu screen is correct and repeatthis procedure if necessary.


2.4.7.4 Setting the Panel Setup selections

1. From the function menu screen, select and enter ‘PANEL SETUP’ to access thepanel setup menu screen.

2. Four selections are available: ‘LANGUAGE’, ‘TYPE (STATE)’, ‘GROUP’ and ‘PASSWORD’.

TYPE & STATE Selection: These parameters register the equipment typenumber and Master/Slave paralleling configuration.

3. From the panel setup menu screen, select and enter ‘TYPE’ _(‘STATE’).Note: The first selection, ‘LANGUAGE’, was completed earlier in this procedure– (See paragraph 2.4.4) .

4. Using the ‘UP’ and ‘DOWN’ menu buttons:

a) Enter the ‘TYPE’ of UPS system – in this case enter ‘7200’.

b) Enter the UPS system ‘STATE’ – in the case of a “single module” systementer the word ‘MASTER’.

5. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the panel setupmenu screen.

GROUP & UPS Selection: This selection sets the communications addressfor the UPS Module.

6. From the panel setup menu screen, select and enter ‘GROUP’ _ ‘UPS’.

7. Using the ‘UP’ and ‘DOWN’ menu buttons:

a) Enter the ‘UPS’ address – in the case of a “single module” system enter ‘1’unless instructed otherwise.

b) Enter the ‘NODE’ address – in the case of a “single module” system enter‘1’ unless instructed otherwise.

8. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the panel setupmenu screen.

PASSWORD Selection: This selection sets the password which will give re-stricted entry to certain screens once set – i.e. access to a password protectedscreen is possible but no data can be entered or changed. Until now, the defaultpassword (00000000) has been used.

9. From the panel setup menu screen, select and enter ‘PASSWORD’.



Figure 2-20: ‘FUNCTION’ selection menu map ‘NEXT PAGE’ selections

Important Once the eight digit password has been selected and saved into the NVRAM fur-ther changes to the UPS parameters will be inhibited unless the correct passwordis entered. ENSURE THE NEW PASSWORD IS SAFELY RECORDED IN THERELEVANT COMMISSIONING OR SERVICE DOCUMENTATION.

10.Using the ‘UP’ and ‘DOWN’ menu buttons enter an 8-digit password.

11.Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the panel setupmenu screen.


When selected to ‘YES’ and saved, all UPS parameters are reset to zero. The parame-

ter values will then require re-entering into the software

NEXT PAGE MENU


SCREEN

MODEM MENU SCREEN

ON/OFFMENU

SCREEN



Verification:

12.Verify that the data shown on the panel setup menu screen is correct andrepeat this procedure if necessary.


2.4.7.5 Setting the NEXT PAGE selections

1. From the function menu screen select and enter ‘NEXT PAGE’ – this accessesthe next page menu screen (See Figure 2-20).

2. Three selections are available: ‘PC-CONN’, ‘ON/OFF UPS’, ‘RELOAD UPS DATA’.

‘PC-CONN’ Setting: This establishes the UPS software settings to interfacevia a modem to a remote location.

1. From the next page menu screen select and enter ‘MODEM CONNECTION’ toaccess the modem menu screen.

2. From the modem menu screen, select and enter ‘PC-CONN.’.

3. Select either ‘LOCAL’ or ‘REMOTE’ modem connection as appropriate.

4. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the modemmenu screen.

5. From the modem menu screen, select and enter ‘RESET’.

6. Select either ‘NO’ or ‘YES’ as appropriate. Note: Selecting ‘YES’ will enable any alarm to be reset from a connected PC.

7. Press ‘ENTER’ to save the settings, then press ‘ESC’ to return to the modemmenu screen.

8. Verify that the data shown on the modem menu screen is correct and repeatthis procedure if necessary.

9. Step back to the next page menu screen by pressing ‘ESC’.

‘ON/OFF UPS CONTROL’ Setting: The on/off menu screen allows theUPS inverter, static bypass line, and rectifier sections to be switched on or offfrom the control panel and will be covered in the power checks.

‘RELOAD UPS DATA’ Setting : Setting this option to YES resets themicro-processor NVRAM to the default parameters and should be carried outonly if a complete reprogramming sequence is required.

WARNING DO NOT enter a ‘RELOAD UPS DATA’ selection while the UPS is on load, as itwill disable the inverter, rectifier and bypass sections, and remove load power.

10.From the next page menu screen select and enter ‘RELOAD UPS DATA’. and ifyou wish to reset the stored data to the default parameters select ‘YES’.

11.Using the setup menu screen locate and enter the ‘POWER’ screen and Re-enterthe units KVA rating.

12.Turn the UPS off for 5 seconds then turn it back on

13.Step back to the default screen by repeatedly pressing ‘ESC’. The UPS func-tion menu parameters have now all been stored in NVRAM



Section 2: 1

2.5 Power checks

Once the UPS parameters have been entered into the software, full power can beapplied to the unit and the following power checks carried out.

WARNING Ensure that the load is isolated or safe to receive power, before continuing withthe following procedure

2.5.1 Applying power to the UPS

1. Check that the Bypass Isolator Q2 is still closed – close Q2 if it is open.

a) Verify that the LCD shows the default screen.

b) Verify that the Amber ‘Load on Bypass’ LED is flashing.

2. Close the UPS Input Isolator Q1.

a) Verify that after approximately 30 seconds the Green ‘Load on Inverter’LED illuminates and the ‘Load on Bypass’ LED extinguishes.

b) The LCD default screen indication should be:

3. Close the Output Isolator Q4.

4. Close the Battery Circuit Breaker (located in the battery cabinet or adjacent toany external battery racks).

a) The LCD default screen indication should be:

2.5.2 Monitoring & recording the UPS operating parameters

5. Using the menu screen navigation techniques described earlier in this section,access the main menu screen and then access the measurement menu screen –a menu map is shown in Figure 2-21.

6. From the measurement menu screen select and enter ‘INPUT’ then note andrecord indicated input voltage in the appropriate commissioning documenta-tion.

7. From the measurement menu screen select and enter ‘BATTERY’ then note andrecord in the appropriate commissioning documentation the battery voltage,current, and percentage charge.

8. From the measurement menu screen select and enter ‘TEMPERATURE’ then noteand record the indicated temperatures in the appropriate commissioning doc-umentation:

BATTERY BREAKER OPEN

OUTPUT SWITCH OPEN

24-09-95 14:33:00

DEFAULT SCREEN

NORMAL OPERATION

24-09-95 14:33:00

DEFAULT SCREEN

s2-c2c.fm5 - Issue 3 Dated 09/11/98 2-47


Figure 2-21: Menu tree for the MEASUREMENT parameters (Issue 5 software)

9. From the measurement menu screen select and enter ‘OUTPUT’ then furtherselect and record in the appropriate commissioning documentation:– output voltage– output current– output power– output frequency.

MEASUREMENT MENU

MAIN MENU SCREEN

SCREEN

DEFAULT MENU SCREENS

INITIALISATIONSCREEN

2-48 s2-c2c.fm5 - Issue 3 Dated 09/11/98


Figure 2-22: Menu tree for the ‘FUNCTON’- ‘NEXT PAGE’ test selections

10.Navigate back to the default screen by repeatedly pressing the ‘ESC’ button.

2.5.3 Power module ON/OFF functional checks

The UPS power sections can be independently switched off and on from the Op-erator Control Panel, as checked below, which enables each section to be testedindividually.

2.5.3.1 Accessing the ON/OFF menu screen

The following functional checks are carried out from the ON/OFF menu screen.To gain access to this screen:


NEXT PAGE MENU


SCREEN

MODEM MENU SCREEN

ON/OFFMENU

SCREEN



1. Using the menu navigation methods described previously, step from thedefault screen via the main menu screen (‘FUNCTION’), password screen, func-tion menu screen (‘NEXT PAGE’) and next page menu screen (‘ON/OFF UPS CON-

TROL’) to the ON/OFF menu screen. Refer to the menu maps in Figure 2-18, Figure 2-19 and Figure 2-22 forassistance if necessary.

2.5.3.2 Inverter test

1. Gain access to the ON/OFF menu screen (See paragraph 2.5.3.1).

2. From the ON/OFF menu screen, select and enter ‘INVERTER’.

3. Using the ‘UP’ menu button, select ‘INVERTER OFF’, then press ‘ENTER’ to savethe selection.

4. On the UPS mimic, verify that the inverter has turned off and the load hastransferred to the static bypass supply.

a) The green ‘Load on Inverter’ LED is extinguished and the amber ‘Loadon Bypass’ LED is flashing.

5. Step back to the default screen, by continually pressing the ‘ESC’ button, andverify that:

a) The ‘INV: OFF VIA DISPLAY’ and ‘LOAD ON BYPASS’ alarms are present.

6. Repeat steps 1 and 2 to return to the ON/OFF menu inverter selection screen.then select ‘INVERTER ON’ and press ‘ENTER’ to save the selection.

7. On the UPS mimic, verify that the inverter has turned on and the load hastransferred back to the inverter from the static bypass supply.

a) The green ‘load-on-inverter’ LED is illuminated and the amber ‘load-on-bypass’ LED is extinguished.


a) The ‘NORMAL OPERATION’ status indication is present.

2.5.3.3 Bypass test


2. From the ON/OFF menu screen, select and enter ‘LINE’.

3. Using the ‘UP’ menu button, select ‘BYPASS OFF’, then press ‘ENTER’ to savethe selection.

4. Step back to the default screen, by continually pressing the ‘ESC’ button, andverify that the ‘BYP: OFF VIA DISPLAY’ (bypass remotely inhibited), is displayed.

5. Repeat steps 1 and 2 to return to the ON/OFF menu line selection screen. thenselect ‘BYPASS ON’ and press ‘ENTER’ to save the selection.

6. Step back to the default screen, by continually pressing the ‘ESC’ button, andverify that the ‘NORMAL OPERATION’ status indication is present.

2.5.3.4 Rectifier and battery autonomy test




2. From the ON/OFF menu screen, select and enter ‘RECTIFIER’.

3. Using the ‘UP’ menu button, select ‘RECTIFIER OFF’, then press ‘ENTER’ to savethe selection.

4. Verify that the rectifier has turned off and the inverter is still operating frombattery power.


a) The ‘RECT: OFF VIA DISPLAY’ and ‘ON BATTERY’ alarms are present.

b) The green battery bargraph LEDs indicate the remaining battery time.Note: If the UPS is allowed to run in this condition the battery bargraphLED’s will progressively turn off indicating the remaining autonomy time.

6. Step forward to the measurements menu screen (See paragraph 2.5.2), thenenter and select ‘BATTERY’, and note and record the indicated remainingautonomy time. Each illuminate bar-graph segment is equivalent to 2 minutesremaining. All 5 will be illuminated for greater than 10 minutes.

7. Step back to the default screen, by continually pressing the ‘ESC’ button.

8. Repeat steps 1 and 2 to return to the ON/OFF menu rectifier selection screen.then select ‘RECTIFER ON’ and press ‘ENTER’ to save the selection.

9. Verify that the rectifier turns on.

10.Step back to the default screen, by continually pressing the ‘ESC’ button, andverify that the ‘NORMAL OPERATION’ status indication is present.

11.Step forward to the measurements menu screen (See paragraph 2.5.2), thenenter and select ‘BATTERY’, and note and record the indicated capacity charge.

12.Step back to the default screen, by continually pressing the ‘ESC’ button.

2.5.4 Battery test

A software-controlled battery test facility can be initiated from the Operator Con-trol Panel on an “immediate” or “periodic” basis. This test turns off the rectifierand runs the inverter (and load) from the battery for a predetermined period. If thebattery voltage falls below a preset minimum level prior to the termination of thetest period a ‘BATTERY FAIL’ alarm is annunciated and the rectifier is immediatelyturned on to prevent the load transferring to bypass – and recharge the battery.

The instructions given below initiates an immediate battery test.

For the following test to be ‘meaningful’ as part of the UPS commissioning pro-cedure, the batteries should be fully charged prior to the test being carried out. TheUPS rectifier section must therefore be allowed to operate with the battery con-nected for several hours to provide the battery with an adequate initial charge.

Caution Do not continue with this procedure if the battery has not yet been charged

1. Using the menu navigation methods described previously, step from thedefault screen via the main menu screen (‘FUNCTION’), password screen, func-tion menu screen (‘BATTERY TEST’) to the battery test menu screen. Refer to the menu map in Figure 2-23 for assistance if necessary.

2. From the battery test menu screen, select and enter ‘SETUP’.



Figure 2-23: Menu tree for the ‘FUNCTON’- ‘BATTERY TEST’ selections (Issue 5 software)

3. Verify that the parameters entered in the battery test setup menu are appropri-ate. If not then enter the correct setup parameters (See paragraph 2.4.7.2).

4. Press ‘ESC’ to return to the battery test menu screen.

5. From the battery test menu screen, select and enter ‘NOW’.

6. Using the ‘UP’ menu button, select Yes (‘Y’), then press ‘ENTER’ to initiate an‘immediate’ battery test.

7. Verify that the rectifier enters the test mode by confirming that LED H1(Amber) is illuminated on the Rectifier Logic Board. (The inverter will con-tinue its operation and discharge the battery.)

8. Step back to the default screen, by continually pressing the ‘ESC’ button andverify that the ‘ON BATTERY’ and ‘RECT: SOFTWARE BLOCK’ alarms are displayed.The green LED battery bargraph will indicate the remaining battery time.Note: If the UPS is allowed to run in this condition the battery bargraphLED’s will progressively turn off indicating the remaining autonomy time.

9. The battery will be tested for the selected ‘DURATION’ time after which theUPS will revert to normal operation.– the rectifier will return to the Float mode.– LED H3 (green) will be illuminated on the Rectifier Logic Board.Note: If the battery fails the test (i.e. falls below the ‘THRESHOLD’ value beforethe ‘DURATION’ time expires), the rectifier will immediately return to the float

FUNCTION MENU

BATTERY TEST MENU SCREEN

SCREEN

BATTERY TEST SETUPMENU SCREEN

Date & Time of NEXT periodic test



mode and the ‘BATTERY FAIL’ alarm will be displayed on the default screen.This alarm can be reset by pressing the ‘RESET’ Button (S1) on the UPS LogicBoard.

2.5.5 Emergency remote power off check

1. Ensure that ‘NORMAL OPERATION’ is displayed on the default screen.

2. Remove the link between terminals 10 & 11 on the Auxiliary Terminal Block(X3) (See Figure 2-10). Or open the remote EPO button if installed.

3. Verify that the UPS power sections shut down and ‘CUT-OFF: EMERGENCY’ isdisplayed on the default screen.

4. Refit the link between terminals 10 & 11 on the Auxiliary Terminal Block(X3) (See Figure 2-10). Or close the remote EPO button if installed.

5. Press the Reset Button (S1) on the UPS Logic Board.

6. Verify that the UPS returns to normal operation – ‘NORMAL OPERATION’ dis-played on the default screen.

Figure 2-24: Menu tree for the ‘SETUP’- ‘BATTERY’ selection

2.5.6 Battery boost test (if applicable)

A software-controlled battery boost facility can be initiated from the OperatorControl Panel on an ‘immediate’ or ‘periodic’ basis. This increases the rectifieroutput (dc bus) to the selected boost voltage level for a predetermined period.

The instructions given below initiates an immediate battery boost charge.

WARNING DO NOT APPLY BOOST CHARGE TO SEALED BATTERIES

1. Using the menu navigation methods described previously, step from thedefault screen via the main menu screen (‘SETUP’), password screen, setupmenu screen (‘BATTERY’) to the battery menu screen. Refer to Figure 2-15 and Figure 2-16 for assistance if necessary.

Continued fromFigure 2-16 BATTERY VOLTAGE MENU SCREEN


BATTERY BOOST SETUPMENU SCREEN



2. From the battery menu screen select and enter ‘VOLTAGE’ to access the batteryvoltage menu screen.

3. From the battery voltage menu screen select and enter ‘BOOST CHARGE’ toaccess the battery boost menu screen.Note: The boost parameters (accessed via ‘SETUP’) were entered earlier in thisprocedure (see page 2-37). These may reviewed here if required.

4. From battery boost menu screen, select and enter ‘NOW’.

5. Using the ‘UP’ menu button, select Yes (‘Y’), then press ‘ENTER’ to save theselection, followed by ‘ESC’ to return to the battery boost menu screen.

6. The rectifier should now be in its boost charge mode.

a) Verify that the boost charge indicator LED H2 (green) is illuminated onthe Rectifier Logic Board.

b) Step back to the main menu screen and then access the measurement menuscreen (See Figure 2-21). Verify that the battery voltage has increased tothe appropriate boost charge level.

7. The rectifier will revert to its float charge mode (LED H3 illuminated andLED H2 extinguished on the Rectifier Logic Board) in the event of:

a) The selected ‘DURATION’ time being reached.

b) The battery charge current falling below the boost ‘THRESHOLD’ currentprior to the completion of the boost ‘DURATION’ time.

c) Manual intervention turning OFF the boost charge facility.Note: this is achieved by changing the ‘NOW’ parameter to No (‘N’) in thebattery boost menu screen (see steps 6 & 7 above).

8. Step back to the default screen, by continually pressing the ‘ESC’ button.

2.5.7 On-Generator test (if applicable)

The following test checks the operation of the generator parameters set-up earlier(See paragraph 2.4.7.3) in the generator menu screen (See Figure 2-19).

The test is unnecessary if the generator parameters have not been selected – i.e.the function parameters for the ‘GENERATOR’ options must be selected to Yes (‘Y’).Any combination of the three functions can be selected.

1. To initiate this test, the generator must apply a voltage in the range12-24Volts (ac or dc) between pins 5 and 6 of the Alarm Interface Board ter-minal block X5 when the generator is operating.

2. Start the generator.

3. On the default screen, check for the following alarms:

a) ‘INV: UNSYNCHRONIZED’The UPS will not synchronise to the unstable generator supply

b) ‘CHARGER INHIBITED’The battery current is inhibited due to the generator power being limited.

c) ‘REDUCED CURRENT LIMIT’The rectifier current is inhibited due to the generator power being limited.

4. Stop the generator



5. Verify that ‘NORMAL OPERATION’ is displayed on the default screen.

2.6 Commissioning conclusion (‘single module’)

1. The (‘single’) UPS module has now been commissioned and can be put intonormal service. Be sure that the commissioning records are completed andfiled appropriately.

2. If the password protection system is to be enabled ensure that the link isremoved from jumper X26 pins 7-8 on the UPS Logic Board.Note: If the password protection system is enabled only those parameterslisted below are changeable without first entering the selected password:• Time and Calendar• ON/OFF UPS CONTROL (rectifier, inverter and bypass)• Battery test (star, time/date stamp, repetition rate)• Modem configuration and operation

1+11+1

3. For 1+1 systems, the commissioning procedure must be repeated for eachmodule. When both modules have been satisfactorily commissioned, con-tinue with the commissioning procedure for the ‘1+1’ system outlined below.

2.7 Parallel System Start Up (‘1+1’ System)

1+11+1

Applies only to The procedures contained in paragraph 2.7 and paragraph 2.8 are used to commis-sion two ‘1+1-configured’ modules as a ‘parallel-operating’ system. It is crucialthat both modules have passed the single module commissioning checks beforeany attempt at paralleling is carried out.

2.7.1 Initialisation

1. Ensure that both modules are fully powered down.

2. On each module in turn:

a) Fit the 60 way flat ribbon cable between the Parallel Logic Board(4520075B) connector X1 and UPS Logic Board (4550007H) connectorX7 – this cable was removed earlier in the commissioning procedure toallow the modules to operate in their ‘single module’ mode.

b) Reconfigure the UPS Logic Board (4550007H) jumpers for parallel opera-tion (See Table 2-13) – these were changed earlier in the commissioningprocedure to allow the modules to operate in their ‘single module’ mode.

c) Check that the Parallel Logic Board (4520075B) jumpers have beenselected in accordance with Table 2-10.



Table 2-13: UPS Logic Board jumper configuration

Note: *X34 must be in position 1-2 for ‘1+1’ operation.X26 must be in position 7-8 to override the password security control.

2.7.2 Parallel logic PCB calibration

Complete paragraph 2.7.2 for each module in turn, ensuring that only the moduleunder calibration is energised.

1. Ensure that switches Q1, Q2, Q3 on the UPS Logic Board are selected OFF –i.e. to disable the rectifier, inverter, and bypass operation.

2. Ensure that all power isolators are OPEN, take particular care that the bypassisolator Q2 is OPEN.

3. Close the rectifier power isolator Q1 to energise the control electronics.

Governing Voltage Controlled Oscillator (GVCO) calibration:

4. Connect a DVM to X8 pin 1 and check that the level is high (+5V) to ensurethat the G.V.C.O. is free running (0V is available at TP10).

5. Adjust R18 to obtain a 50Hz square wave at X8 pin 2. Note: for 60Hz opera-tion connect jumper X7 to 1-2 and adjust R18 for 60.00Hz @ X8 pin 2.

Reverse/Forward current detector calibration: .

6. Connect a DVM to the lower end of R68.

7. Adjust R19 to obtain the appropriate voltage for the expected nominal outputcurrent as shown in Table 2-14.

Table 2-14:

Software re-configuration:

X26

1 - 2Inverter operation in ‘Manual’ mode (Bypass preferred) = ClosedInverter operation in ‘Auto’ mode (Inverter Preferred) = (Standard)

3 - 4Inverter Bad voltage for 10 secondsOff latch enabled = Closed (Standard)Off latch disabled = Open

5 - 6 Not Required

7 - 8Security Password Over-ride. Closed = Over-ride security Password Open = Enable security Password (standard)

X341 - 2 *G.V.C.O. to inverter logic = parallel module

2 - 3 Micro V.C.O. to inverter logic = single module





UPS Rated Voltage R68 Lower End Value

220/380V 5.90V

230/400V 6.20V

240/415V 6.45V



8. Using the software driver menu display screens enter the ‘SETUP’ menu (SeeFigure 2-15).

9. Select and enter the ‘CONFIG’ screen.

10.Using the ‘ROTATE’ button select ‘PAR 1+1’ and press ‘SAVE’ to store the param-eters into memory.

11.Using the ‘ESCAPE’ button return to the ‘DEFAULT’ alarms screen.

12.Ensure the procedures detailed in paragraph 2.7.2 are carried out individuallyon both modules.

2.8 Testing the Complete Parallel System

2.8.1 Module starting

1. Ensure that the bypass input isolator Q2 remains OFF on both modules.

2. Ensure that the switches Q1, Q2 & Q3 on the UPS Logic Board are OFF.

3. Close the rectifier input isolator Q1 on each module.

4. Start the rectifier in each module by closing the UPS Logic Board switch Q3and check for the correct battery float voltage on each modules’ ‘MEASURE-

MENT’ screen.

5. Close the appropriate battery isolators for the system configuration.

6. Start a selected inverter by closing switch Q2 on the module UPS LogicBoard and then close the module output isolator Q4 – the inverter should runup and its output contactor K1 close.Check for correct output voltages on the ‘MEASUREMENT’ screen.

7. Start the inverter in the second module by closing switch Q2 on the UPSLogic Board – the second module’s inverter should run up and its output con-tactor K1 close.Check for correct output voltages on the ‘MEASUREMENT’ screen.

8. Using the current ‘MEASUREMENT’ screens or current clamp CTs on the outputcritical busbar interconnecting cables, check for circulating currents betweenthe paralleled inverters.

d) The measured circulating current should be less than 10% of the modules’kVA rating – e.g. 6 amps for a 60kVA unit.

e) Adjust the inverter φ displacement using R247 on the Inverter LogicBoard (4530025T) on one module to minimise the circulating current.

9. Close the bypass input isolators Q2 on each module.

10.Enable the static bypass on each module by closing the switch Q1 on eachUPS Logic Board.The inverters should now synchronise to the bypass supply.

11.Allow the system to stabilise.Check for ‘NORMAL OPERATION’ indicated on the ‘DEFAULT’ screen of eachmodule.



2.8.2 Inverter bypass re-transfer checks

The UPS system can be configured to operate in two ways, i.e.:

Redundant module

Where the proposed rated load level is less than or equal to the nominal kVA ofone module. Either module operating is therefore capable of sustaining the load.

Non-redundant module

Where the proposed rated load level is greater than the nominal kVA of onemodule but less than the sum of both. Both modules are therefore required to sus-tain the load.

2.8.2.1 Redundant configuration system power checks

This paragraph applies to a ‘Redundant’ module system only. If the system undertest is configured as ‘Non-redundant’ then jump to paragraph 2.8.2.2.

The static bypass thyristor switches contained within each module will operate to-gether, always opening and closing in unison. However it is possible to have onein a ‘BLOCKED’ state by selecting switch Q1 of the relevant UPS Logic Board toOFF – simulating a ‘bypass disabled’ condition.

1. Ensure that jumper X6 0-1 is open on the Parallel Logic Board (4520075B)for redundant operation.

2. Start both modules and ensure they operate as expected, with the invertersparalleled and ‘NORMAL OPERATION’ displayed on both modules’ ‘DEFAULT’screen.

3. Stop one module’s inverter by selecting OFF Q2 on its UPS Logic Board.

a) The inverter should stop and the module’s output contactor K1 open –thereby disconnecting the module from the critical bus.

b) The remaining module should continue to operate and support the criticalbus supply.

4. Stop the second module’s inverter by selecting OFF Q2 on its UPS LogicBoard.

a) The second module’s inverter should stop and its output contactor K1open, – thereby disconnecting the second module from the critical bus.

b) Critical bus power should now transfer to the bypass supply, without abreak – i.e. both modules’ bypass static switches should close.

5. Check for the appropriate default alarms on each module mimic display.

6. Start the inverter on one module by selecting ON Q2 on the relevant module’sUPS Logic Board.

a) The inverter should run up and achieve synchronisation.

b) The critical bus should transfer to the inverter – i.e. the output contactor(K1) should close in the running module only, and the static switchesshould open in both modules.

7. Start the remaining module’s inverter by selecting ON Q2 on its UPS LogicBoard.

a) The inverter will run up and achieve synchronisation.



b) Check that the LED H3 illuminates on the Parallel Logic Board during‘slave’ mode operation.

c) The second module’s output contactor (K1) should close connecting theinverter to the critical bus.

d) Check that the LED H3 extinguishes on the Parallel Logic Board, indicat-ing ‘master’ mode operation.

2.8.2.2 Non-redundant configuration system power checks

This paragraph applies to ‘Non-redundant’ configured systems only. If the systemunder test is configured as a ‘Redundant’ system then jump to paragraph 2.9.

The static bypass thyristor switches contained within each module will operate to-gether, always opening and closing in unison. However it is possible to have onein a ‘BLOCKED’ mode by selecting OFF switch Q1 of the relevant UPS LogicBoard, simulating a ‘bypass disabled’ condition.

1. Ensure that link X6 0-1 is closed on the Parallel Logic Board (4520075B) for‘Non-redundant’ operation.

2. Start both modules and ensure they operate as expected, with the invertersparalleled and ‘NORMAL OPERATION’ displayed on both modules’ ‘DEFAULT’screen.

3. Stop one module inverter by selecting OFF switch Q2 on the UPS LogicBoard.

a) The inverter should stop and the module output contactor K1 open –thereby disconnecting the module from the critical bus.

b) The output contactor (K1) should also open in the remaining module.

c) If available both modules’ static switches should close to connect the crit-ical bus to the bypass supply.

d) Check on the appropriate module mimic displays for verification.

4. Turn OFF the remaining inverter by selecting OFF switch Q2 on its UPSLogic Board.

a) The second module’s inverter should stop – the load is already on bypass.

5. Start the inverter on one module by selecting ON switch Q2 on the relevantmodule’s UPS Logic Board.

a) The inverter should run up but its output contactor (K1) should remainopen.

b) The load will remain connected to the bypass waiting for the start of thesecond module.

6. Start the second module’s inverter by selecting ON switch Q2 on its UPSLogic Board.

a) The inverter will run up in slave mode – i.e. led H3 on the Parallel LogicBoard will illuminate until the module achieves synchronisation and par-allels with the existing inverter.

b) Both modules should now transfer the critical bus supply to inverter byclosing the output contactor (K1) and turning off the static switch in bothmodules simultaneously.



7. Check on the appropriate module mimic displays for verification.

8. Allow the system to stabilise.Check for ‘NORMAL OPERATION’ indicated on the mimic ‘DEFAULT’ screen foreach module.

2.9 Commissioning conclusion (‘1+1’ system)

1. The (‘1+1’) parallel UPS system has now been commissioned and can be putinto normal service. Be sure that the commissioning records are completedand filed appropriately.

2. If the password protection system is to be enabled (both modules) ensure thatthe link is removed from jumper X26 pins 7-8 on the UPS Logic Board.Note: If the password protection system is enabled only those parameterslisted below are changeable without first entering the selected password:• Time and Calendar• ON/OFF UPS CONTROL (rectifier, inverter and bypass)• Battery test (star, time/date stamp, repetition rate)• Modem configuration and operation



Section 2:

2.10 Voltage and Frequency Conversion

The 7200 Series UPS leaves the manufacturer fully tested and adjusted to operateat 400Vac / 50Hz with a 198 cell battery; however, but can be converted to 380Vor 415V, at either 50 or 60Hz. Such a conversion is effected by:

• changing the control power supply transformers primary tap voltages. • entering the revised working parameters into the control system’s memory

via the Operator Control Panel ‘SETUP’ menus.• amending the number of batteries, if required.

The module’s working voltage and frequency is set as a matter of course withinthe commissioning procedure: the purpose of the following paragraphs is to pro-vide a consolidated procedure for changing these parameters post commissioning– i.e. to change the voltage/frequency of an already working module. Note: Where reference is made to the “nominal” voltage, this should be taken asthe required equipment working voltage – e.g. 380/400/415 volts.

2.10.1 Rating considerations and battery sizing

If the module is to operate at 415V input/output its power capacity will increaseby approximately 10%. – i.e. A 60kVA unit will be increased to 66kVA.

The number of battery elements required to enable the unit to meet its designspecifications is shown in the table below.Note: If additional elements are required they should be of the same type and ca-pacity as those already in use.

Table 2-15: Number of battery elements

2.10.2 Hardware conversion

1. Ensure that the module is completely powered down – i.e. all the UPS isola-tors, including the battery circuit breaker, are open (OFF or in position ‘0’) –if necessary transfer the load to the Maintenance Bypass supply.

2. Select the correct primary voltage tap on the Power Supply transformers T2and T3, according to Table 2-16 below.

Table 2-16: Power supply transformers T2 and T3 voltage selection.

Nominal Operating Output Voltage Specified Nº of Battery Elements

380V AC 192 Cells

400V AC 198 Cells

415 V AC 204 Cells

380V Operation 400V Operation 415V Operation

A3 - B A2 - B A1 - B

s2-c2d.fm5 - Issue 3 Dated 09/11/98 2-61


2.10.3 Software conversion – Entering new voltage / frequency / battery data

Figure 2-25: ‘SETUP’ menu map (Issue 5.0 software)

1. Inhibit the UPS power sections by selecting switches Q1, Q2, Q3 on the UPSLogic Board to OFF.

2. Close the Bypass Isolator Q2.

a) The power supply and electronics will energise.

b) The Operator Control Panel display will power up.

c) The rectifier and inverter power sections will remain off.



SETUP MENU SCREEN

MAIN MENU SCREEN

UPS MENU SCREEN

VOLTAGEMENU

SCREEN

FREQUENCYMENU

SCREEN

BATTERYMENU

SCREEN

2-62 s2-c2d.fm5 - Issue 3 Dated 09/11/98


4. Ensure that a link is fitted to jumper X26 pins 7-8 on the UPS Logic Board tooverride the password protection system.

5. Select and enter ‘SETUP’ – the password screen will now be shown.

2.10.3.1 Setting the UPS working voltage parameters

1. From the setup screen, select and enter ‘VOLTAGE’ – this will access the volt-age menu screen.

2. Select and enter ‘RATED VOLTS.’.

a) Press the ‘UP’ menu button repeatedly until the desired input/output work-ing voltage is indicated.

b) Press ‘ENTER’ to save the selection and then press ‘ESC’ once to move backto the voltage menu screen.

3. Select and enter ‘LOWER’.

a) Using the data entry method described above, enter the required input andoutput voltage undervoltage thresholds.Note: Standard settings are for -10% (input) and -10% (output).

b) Press ‘ENTER’ to save the selection then press ‘ESC’ once to move back tothe voltage menu screen.

4. Select and enter ‘UPPER’.

a) Using the data entry method described above, enter the required input andoutput overvoltage thresholds.Note: Standard settings are for +10% (input) and +10% (output).

b) Press ‘ENTER’ to save the selection then press ‘ESC’ once to move back tothe voltage menu screen.

5. Verify that the data shown on the voltage menu screen is correct and repeatthis procedure if necessary.


2.10.3.2 Setting the UPS frequency parameters

Note: go directly to paragraph 2.10.3.3 if the frequency is not to be changed.

1. Select and enter ‘FREQUENCY’ – this will access the frequency menu screen.

2. Select and enter ‘NOMINAL’.

a) Press the ‘UP’ menu button repeatedly until the desired nominal frequencyis indicated.

b) Press ‘ENTER’ to save the selection then press ‘ESC’ once to move back tothe frequency menu screen.

3. Select and enter ‘SYNC WINDOW’.

a) Enter the required sync window limit.Note: Standard setting is ‘2.0%’ – i.e. the inverter will sync to the bypass ifit is ±1Hz of 50Hz nominal.




4. Select and enter ‘SLEWRATE’.

a) Enter the required slew rate (range 0.1 - 1.0 Hz/s).Note: Standard setting is ‘0.10 Hz/s’ – i.e. the speed the inverter will tracka change in bypass frequency.


5. Verify that the data shown on the frequency menu screen is correct and repeatthis procedure if necessary.


2.10.3.3 Setting the Battery parameters

Figure 2-26: ‘SETUP’ – BATTERY MENU

1. From the setup menu select and enter ‘BATT.CELLS’ – this will access the bat-tery menu screen (illustrated in Figure 2-26).

Setting the number of cells:

2. From the battery menu screen, select and enter ‘BATT.CELLS’.

3. Following the data entry method described earlier, using the ‘UP’, ‘DOWN’menu buttons, enter the number of cells contained in the battery string.

WRITE SAVEMOVE EXITBATT.CELLS 198

WRITE SAVEMOVE EXITCAPACITY 052 Ah

WRITE SAVEMOVE EXITEND DIS. 1.67 v/e

WRITE SAVEMOVE EXITBAT.LOW 1.82 v/e

WRITE SAVEMOVE EXITMAX. 2.45 v/e

UPS 0060 kVAVOLTAGE 400 VFREQUENCY 50 HzBATT.CELLS 198








BATTERY VOLTAGEMENU SCREEN


SETUP MENU SCREEN

BATTERY MENU SCREEN





Setting the Battery Capacity:

5. From the battery menu screen, select and enter ‘CAPACITY’.

6. Using the ‘UP’, ‘DOWN’ menu buttons, enter the total battery A/Hr capacity.(at the 10Hr rate C10).


Setting the battery voltage characteristics:

From the battery menu screen, select and enter ‘VOLTAGE’ – this will take you to the battery voltage menu, which is concerned with selecting the battery charging characteristics.

Battery undervoltage trip setting

8. From the battery voltage menu, select and enter ‘END DIS.’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘end-of-dis-charge’ voltage – standard setting is 1.67V/cell.Note: this is the ‘end-of-discharge’ voltage and is the voltage at which thebattery breaker is tripped.


Battery low voltage warning setting

9. From the battery voltage menu, select and enter ‘BAT LOW’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘low battery volt-age’ – standard setting is 1.82V/cell.Note: this is the voltage at which ‘low-battery warning’ annunciates.


Battery overvoltage trip setting

10. From the battery voltage menu, select and enter ‘MAX’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the specified ‘max batteryvoltage’ – standard setting is 2.45V/cell. This sets the ‘slow’ overvoltagelevel which is effective only when the batteries are in the float chargemode, and is the voltage at which, after 3 minutes, the battery breaker istripped, and the rectifier and inverter turned OFF.


Battery boost charge setting:

WARNING DO NOT apply BOOST CHARGE to sealed batteries



Figure 2-27: Battery boost charge parameters

11. From the battery voltage menu, select and enter ‘BOOST CHARGE’ – this willtake you to the boost charge menu screen.

12. From the boost charge menu, select and enter ‘SETUP’ – this will take you tothe battery boost setup menu screen.

13. From the battery boost setup menu, select and enter ‘DURATION’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required boost operationtime (in minutes) – factory setting is 600 mins.


14. From the battery boost setup menu, select and enter ‘THRESHOLD’.

a) Using the ‘UP’, ‘DOWN’ menu buttons, enter the required current change-over threshold – factory setting is 20% of the battery current limit.Note: this is the level that the battery current must reach before boostcharge is enabled upon mains return.


15. It is advisable to set the ‘NOW’ and ‘AUTOMATIC’ parameters to ‘NO’ at thisstage in the commissioning, and reset to ‘YES’ (if required) once the rectifierhas been fully commissioned.

Verification:

16. Press ‘ENTER’ to save the data to memory, then press ‘ESC’ once to return tothe battery voltage menu screen.

17. Verify that the data shown on the battery voltage menu screen is correct andrepeat this procedure if necessary.

Continued fromFigure 2-26 BATTERY VOLTAGE MENU SCREEN




Figure 2-28: Battery CHARGE MODE Selection (Issue 5.0 software)

2.10.4 Calibration conversions

2.10.4.1 Recalibrating the battery charging voltages

This part of the procedure calibrates the battery charging voltages using the ap-propriate potentiometers on the Rectifier Logic Board and requires the rectifier tobe fully powered-up.

1. Connect a DC voltmeter across the battery cable connections (adjacent to thebattery fuse).


NEXT PAGE MENU

FUNCTION

SCREEN

CHARGE MODESELECTION SCREEN

ON/OFFMENU

SCREEN

MENU SCREEN



2. Close the UPS input mains isolator (Q1).

3. Turn switch Q3 on the UPS Logic Board to ON – the rectifier should nowstart and ramp up to float voltage, as indicated on the voltmeter.

Float charge voltage calibration:

4. On the Rectifier Logic Board:

a) Ensure led H3 (green) is illuminated.

b) Adjust R21 to obtain the required float charge voltage, indicated on theDC voltmeter.

Manual charge voltage calibration:

5. Using standard screen navigation techniques, gain access to the charge modeselection screen via the FUNCTION – NEXT PAGE – ON/OFF UPS CON-TROL menu path (See Figure 2-28).

6. Scroll through the menu options and select manual charge mode (‘MAN’).


a) Ensure led H4 (yellow) illuminates (H3 extinguished).

b) Adjust R22 to obtain a charge voltage, indicated on the DC voltmeter,appropriate to ‘forming’ open vented cells (if applicable). If sealed cellsare used then set this voltage to equal the float voltage set previously.

Boost charge voltage calibration:

8. Leave the charge mode selected to manual (‘MAN’), as instructed above.


a) Link-out pins 0-2 on jumper X9 to force the charger to the ‘Boost’ mode.

b) Ensure led H2 (green) illuminates (H4 should extinguish).

c) Adjust R20 to obtain the required boost charge voltage, indicated on theDC voltmeter.Note: If sealed cells are used then set this voltage to equal the float voltageset previously.

Calibration completion:

10. Open the UPS input mains isolator Q1 and bypass isolator S2.

11. On the UPS Logic Board set S1, S2, S3 to ON to re-enable the UPS powersections.

12. On the Rectifier Logic Board remove the link from pins 0-2 on jumper X9.

13. Disconnect and remove the DC Voltmeter.

2.10.4.2 Completion of UPS SETUP configuration

The setup menu parameters have now all been entered and stored in the controlsystem’s non-volatile memory.

1. Start the UPS following the normal start-up instructions and verify that itnow operates at the desired voltage and frequency.

2. If required, remove the link from jumper X26 pins 7-8 on the UPS LogicBoard to re-enable the password security system.


Section 2:

Chapter 3 - Converting single (pre Jan 1997) units to 1+1 capability

3.1 Introduction

Series 7200 single module units manufactured prior to January 1997 will requireupgrading before they can operate in a 1+1 system configuration. This chapteroutlines the procedure to be followed before the units are commissioned.

Before the 1+1 paralleling option can be fitted the upgrade procedure requires me-chanical changes to be made by fitting Modification Kit Part Nº 4641030E, whichthen changes the unit part number as shown below.

Table 2-17:

3.1.1 Important Considerations

Caution This modification must be carried out only by a fully trained and authorised Liebertengineer.

Allow approximately two hours for the modification of each module.

The mechanical relocation of existing PCB’s and control transformers must becarried out prior to fitting the 1+1 parallel option kit Part N º 4645004A.

Step by step instructions are included with the conversion kit Part Nº 4641030Ebut are not in the scope of this manual. However the basic mechanical differencesand repositioning of components is shown in Figure 2-29.

3.2 Conversion Procedure

1. Fit the conversion kit Part Nº 4641030E, follow the instructions suppliedwith each kit.

2. Upgrade the PCB’s, refer to below.

Units manufactured after January 1997 will have the new PCB’s factory fitted.

Model Rating kVA

Pre January 1997 unit Part Nº

Modification Kit Required

Converted Unit Part Nº

30 5410303P 4641030E 5410305R

40 5410304Q 4641030E 5410307T

60 5410308U 4641030E 5410310W

PCB DescriptionRemove PCB Pre Jan. 97

Fit New PCB Post Jan. 97

Inverter Logic 4530024S 4530025T

UPS Logic 4550004E 4550007H

Static Switch 4542041X 4542043Z

s2-c2d2.fm5 - Issue 3 Dated 09/11/98 2-69


Figure 2-29: Pre/Post modification mechanical layouts

3. Check the software version on the UPS Logic Board (D35/D36) and Opera-tor Logic PCB (D8). This must be Version 3.0 or later. If the software versionis incorrect, replace these devices according to the table below

Table 2-18: .

On completion of the mechanical conversion, PCB replacement and software upgrade, the converted unit should be commissioned as detailed in Chapter 2.

45

300

25T

4550007H

Pre January 1997 unit before conversion Pre January 1997 unit after conversion.

Factory supplied units post Jan 97

EEPROM Old Part Number New Part Number

D35 0837044A Rev x.xx 0837044A Rev D.00

D46 0837045B Rev x.xx 0837045B Rev D.00

D8 0837046C Rev x.xx 0837046C Rev D.00

2-70 s2-c2d2.fm5 - Issue 3 Dated 09/11/98

Commissioning Report Sheet

Section 2 : Commissioning Parameter Settings

Sample Commissioning Recordsheets System Details

SET UP MENU Parameters

Customer Site Details

Module Type/Rating

Module Part/Serial Number

MenuSelection

ParameterStandard Factory Setting

RangeSelected Setting

Min. Max

UPS KVA VALUE 60kVA – –

UPS TYPE 3 Phase – –

CONFIGURATION Single – –

VOLTAGE NOMINAL INPUT VOLTAGE 230 220 240

INPUT UNDERVOLTAGE –10% –1% –99%

INPUT OVERVOLTAGE +10% +1% +99%

NOMINAL OUTPUT VOLTAGE 230 220 240

OUTPUT UNDERVOLTAGE –10% –1% –99%

OUTPUT OVERVOLTAGE +10% +1% +99%

FREQUENCY NOMINAL FREQUENCY 50 Hz 50Hz 60Hz

SYNC WINDOW 2% 0.5% 9%

SLEW RATE (SPEED) 0.1 Hz/Sec 0.1 1.0

BATTERY NUMBER OF CELLS 198 190 210

CAPACITY 85 AHr 000 499

END OF DISCHARGE VOLTS 1.67 Volts/cell 1.60 1.69

LOW BATTERY VOLTAGE 1.82 Volts/cell 1.70 1.89

MAX. BATTERY OVER VOLTAGE 2.40 Volts/cell 2.30 2.70

BOOST CHARGE ENABLE NO – –

BOOST CHARGE AUTO NO – –

BOOST CHARGE DURATION 0000 min. 0000 9999

BOOST CHARGE THRESHOLD 00 Amps 00 99

S2-c2e.fm5 - Issue 3 Dated 09/11/98


MAINTENANCE MENU Parameters

MenuSelection Parameter

Standard Factory setting


Min Max

PASSWORD PASSWORD 0000 0000 –

S.N. SERIAL NUMBER 0000 0000 –

12.00.00 CURRENT TIME AND DATE 12.00.00 01.01.96

–

LAST SER. LAST SERVICE TIME AND DATE 01.01.96 –

NEXT SER. NEXT SERVICE TIME AND DATE 01.01.96 –



FUNCTION MENU Parameters

MenuSelection

ParameterStandard Factory setting


Min Max

Input Password To Gain Access To Function Selec-tion Screen

0000 0000 0000 0000

9999 9999

BATTERY TEST

NOW NO – –

AUTOMATIC NO – –

SETUP DURATION 00 Min 00 99

THRESHOLD 1.70 V/e 1.70 1.90

PERIOD 000 dd 000 999

START AT 01.01.96 – –

GENERATOR INV: SYNC INHIBIT NO – Requires an alarm

inter-face PCB fitted

BAT: I INHIBIT NO –

RECT: I INHIBIT NO –

PANEL SETUP

LANGUAGE ITALIAN Eng : Fr : Esp : Deu.

TYPE MASTER. 0060 – –

GROUP UPS : NODE : 1 : 1 – –

PASSWORD 0000 0000 0000 0000

9999 9999

MODEMCONNEC-TION

PC CONN LOCAL – –

RESET NO – –

ON/OFF UPS BLOCK

INVERTER ON – –

BYPASS ON – –

RECTIFIER ON – –

RECTIFIER FLO FLO MAN

RELOAD UPS DATA

RELOAD DATA NO DO NOT perform this test as part of the normal commissioning procedure unless the UPS parameters have to be reset to

factory default values.



MEASURMENT MENU Parameters

Selection Screen

ParameterStandard Factory setting

EnterOn Site Readings

OUTPUT VOLTAGE A – B 400 Volt

B – C 400 Volt

C – A 400 Volt

A – N 230 Volt

B – N 230 Volt

C – N 230 Volt

CURRENT A 0 Amp

B 0 Amp

C 0 Amp

N 0 Amp

POWER A 0 kW

B 0 kW

C 0 kW

A 0 kVA

B 0 kVA

C 0 kVA

FREQUENCY Bypass Line 50 Hz

Inverter 50 Hz

INPUT VOLTAGE A – B 230 Volt

B – C 230 Volt

C – A 230 Volt

BATTERY VOLTAGE 460 Volt

CURRENT 0 Amp

CHARGE CAPACITY 100%

TEMPERATURE Tt (Transformer) –

Ta (Input air) –

To (Output air) –

Tb (Batt cabinet) –



Hardware Parameters

Rectifier Logic Board

Parameter Potentiometer Test Point Factory setting

Site Setting

Rectifier Current Limit R17 X8 pin 7 Proportional kVA

Battery Current Limit R18 X8 pin 8 Proportional kVA

Battery Temperature Compensa-tion

R121 X8 pin 5 2.98Vdc

DC Float Voltage R21 DC Bus 449Vdc

DC Manual Voltage R22 DC Bus 449Vdc

DC Boost Voltage R20 DC Bus 449Vdc

DC Test Voltage R19 DC Bus 390Vdc

Inverter Logic Board


Site Setting

150% Current limit R248 X10 pin 4 0.6Vdc

Inverter Tri-wave PWM reference

R241 Scope to LHS of R27 4Vp-p (+2V to -2V)

Output Voltage R-N R246 Inv output terminal R-N 230Vac

Output Voltage S-N R244 Inv output terminal S-N 230Vac

Output Voltage T-N R245 Inv output terminal T-N 230Vac

Output Voltage R-S R242Adjust all 3

phases together

Inv output terminal R-S 400Vac

Output Voltage S-T Inv output terminal S-T 400Vac

Output Voltage R-T Inv output terminal R-T 400Vac

Output Frequency R-T – Inv output terminal R-T 50Hz

Inverter/Bypass phase shift

R247 Scope Bypass R-phase and Inv R-phase.

0° Shift

UPS Logic Board


Site Setting

5V Voltage reference R209 X20 pin 1 5.00Vdc

2.5V Voltage reference R212 V45 anode 2.50Vdc



Battery information

Operator Logic Board


Site Setting

LCD Display Contrast R21 LCD Display N/A

Parameter On-Site notes

Battery Type

=

Number of Cells

Float Voltage

Ampere/Hr capacity

Battery Current Limit

Battery Breaker Size

ENGINEER’S NAME:

SIGNATURE:

DATE:

WITNESSED BY:

SIGNATURE

DATE:


sect-2

Documents

battery installation

battery parameters

control cable installation

ups power cables

power checks

ups setup parameters

ups frequency parameters

ups maintenance parameters